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Outback Power Systems Outback Power Systems Battery Charger User Manual

1. AC HOT QUT i po EE MATE 20272 69 200 S un AC LOADS Er MASTER MATE 18 230VAC AC OUT 00006 NEUTRA se men Cries HUB 4 OR HUB 10 120 AMPS AC IN z be dica o o Oset ele elelele elelole L 6 SLAVE A ewa r a ad ses Ah hveasd JE 2 on J oa on on AC OUT A IIL NORMAL 4 P ss omea T aa mee Ee NEUIRA Gea CBI 30 AMP OUTPUT PALE EE DA 30A 204 304 04 304 B04 304 a BREAKERS W OUTPUT INPUT INPUT AC IN ele elelele olelelo s s x FOUR CBI 30 ANP AC OUT SLAVE INPUT BREAKERS det NEUTRAL Catt 20 AMPS AC IN a AX K AC HOT IN AC SOURCE 2 lg SLAVE AC DU 20V a PANAL A EUTRAL Gea o e AC IN NEUTRAL k AC BOX judu FX DC B k ALL BREAKERS SHOWN AC LOADSPeOA MAX 2 POLE m L da s BYPASS MECHANISM es a af 1204 BYPASS lev 2504 BRKRS 12V 2504 BRKRS Sree ee innen 1 aa 4 30A la s PTT St LADA BRERS 24V 1754 BRKRS THE DUTBACK PSAC OUTPUT 48V 1004 BRKRS 48V 1754 BRKRS C JE BREAKERS l e FX Cut Baek aa gt BKW 4 FX2012E 4 FX2024E Power Systems AC SOURCE hoa MAX cay 304 BATTERY 92KW 4 FX2348E 19009 62nd AVE NE 23OVAC INPUT ta aff FX Na oi ere 10 4KW 4 VFX2612E HI asa WA 98223 BREAKERS lt a 5 6030 L 12KW 4 VFX3024E 4 VFX3048E 8 12KW 120A BYPASS PAR
2. ADV FX PAGE1 choose category ADV INV CHGR PG2 ADV FX PAGE2 choose category PG1 GRID GEN PG3 ADV FX PAGE3 choose category PG2 AUX STACK PG4 ADV FX AUX POO aux output AUTO control DOWN INC DEC PORT ADV FX AUX POO aux output AC Drop function DOWN INC DEC PORT ADV FX AUX POO aux output DivertAC function DOWN INC DEC PORT ADV FX AUX POO aux output DivertDC function DOWN INC DEC PORT ADV FX AUX POO aux output Cool Fan function DOWN INC DEC PORT ADV FX AUX POO aux output Vent Fan function DOWN INC DEC PORT ADV FX AUX POO aux output Fault function DOWN INC DEC PORT ADV FX AUX POO aux output GenAlert function DOWN INC DEC PORT ADV FX AUX POO aux output LoadShed function DOWN INC DEC PORT ADV FX AUX POO aux output Remote function DOWN INC DEC PORT Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Once the password has been correctly entered the ADV CHOOSE CATEGORY screen is displayed Selecting lt PG2 gt shows a second screen of categories Selecting lt PG3 gt shows a third screen of categories Selecting lt AUX gt allows adjustment of the auxiliary output set points and operation The AUX OUTPUT CONTROL screen allows selection of the mode of the AUX output Selecting INC or DEC
3. Program the top FX as Master 1 2PH MASTER and the three lower FX s as OutBack L1 Slaves OB SLAVE L1 NOTES The AC OUTPUT NEUTRAL IS NOT BONDED TO THE CHASSIS OR THE GROUND TERMINAL of the FX system This connection is to be made by the installer either in the AC service entrance or within the AC load distribution panel of the electrical system The AC input AC output and DC terminals are isolated from the metal chassis of the FX Proper grounding of these circuits and the chassis of the FX is the responsibility of the installer Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 20 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 FX SYSTEM CONFIGURATION 3 PHASE FX SYSTEM 3 Phase FX System The following diagram illustrates a typical 3 phase FX installation using three FX s This system will produce 230VAC per phase and 400VAC from phase to phase At this time there can only be one FX per phase on a 3 phase system For this type of installation use of OutBack Power Systems PS 3PH system is recommended This FX system will require six OBDC 30 CBI breakers for the AC input and AC output and one OBDC 30T CBI breaker for the AC bypass Additional breakers can be purchased and installed in the PSAC if necessary The AC wiring from the AC source and to the AC loads must handle 30 amps AC
4. STATUS FX BATT P00 refloat 12 5 vdc set point DOWN UP TOP PORT STATUS FX BATT P00 egualize 14 4 vdc set point DOWN UP TOP PORT STATUS FX BATT P00 equalize 00 0 hrs time remaining DOWN UP TOP PORT STATUS FX BATT P00 battery temp 255 not in degrees C F DOWN UP TOP PORT STATUS FX BATT end of battery menu UP TOP STATUS Copyright 2003 OutBack Power Systems Inc MODES Shows status and allows adjustment of Inverter AC input Charger Aux and EQ METER Provides the AC voltages and currents of the FX lt BATT gt Provides the battery voltage and charger set points and timers PG2 Displays additional sections ERRORS WARNINGS and PG3 Selecting BATT displays the ACTUAL BATTERY voltage measured by the FX If the RTS battery temperature sensor is not connected then the actual battery voltage will egual the temperature compensated battery voltage Selecting lt DOWN gt advances the display to the next item in the battery menu Selecting STATUS returns you to the Status screen Selecting PORT allows viewing of the next FX connected to the MATE This menu displays the TEMPERATURE COMPENSATED BATTERY VOLTAGE which is used by the battery charger for regulation The Remote Temperature Sensor RTS must be connected to the Master FX for temperature compensation If the RTS is connected then this value will be higher than the ACTUAL BATTERY VOLTAGE when the battery is hot a
5. STATUS FX WARN P00 airtemp 206 DOWN UP PORT STATUS FX WARN P00 fettemp 200 DOWN UP PORT STATUS FX WARN P00 captemp 203 DOWN UP PORT STATUS FX WARN end of warnings menu UP TOP STATUS Copyright 2003 Tel 360 435 6030 Fax 360 435 6019 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA PG1 Returns to page 1 of the STATUS section ERROR Displays the different causes for errors and gualifies each cause with a Yes or No lt WARN gt Displays the different causes for warnings and gualifies each with a Yes or No PG3 Displays additional sections reason for last DISCONNECT and SELL AC IN FREOUENCY TOO HIGH indicates that the FX is approaching the upper limit of its freguency window and will drop the AC source if the frequency gets much higher If the frequency of the AC source is above 55 Hz the FX will display this warning AC IN FREQUENCY TOO LOW indicates that the FX is approaching the lower limit of its frequency window and will drop the AC source if the frequency gets much lower If the frequency of the AC source is below 45 Hz the FX will display this warning AC IN VOLTAGE TOO HIGH indicates that the AC source s voltage is over the upper limit default is 270 VAC of its voltage window If an AC source was just applied to the FX the FX will not connect to the AC source until the voltage drops below the upper limit AC IN VOLTAGE TOO LOW indicates
6. choose category PG3 SELL CAL MAIN ADV FX CALIBRATE P00 vac input 230 vac adjustment DOWN INC DEC PORT ADV FX CALIBRATE P00 vac output 230 vac adjustment DOWN INC DEC PORT ADV FX CALIBRATE P00 battery vdc 12 8 vdc adjustment DOWN INC DEC PORT ADV FX CALIBRATION calibration setup completed TOP ADV MAIN Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Once the password has been correctly entered the ADV CHOOSE CATEGORY screen is displayed Selecting lt PG2 gt shows a second screen of categories Selecting lt PG3 gt shows a third screen of categories Selecting lt PG4 gt shows a fourth screen of categories Selecting lt CAL gt allows calibration of the AC input AC output and battery voltage set points The VAC INPUT ADJ USTMENT allows calibration of the AC input voltage If the AC source is measured and is different than the value read from the MATE the user can adjust the reading to match the measured value This value can be raised by pressing the INC button Conversely this value can be lowered by pressing the DEC button The value can be raised or lowered 4 vac The VAC OUTPUT ADJ USTMENT allows calibration of the AC output voltage If the AC output is measured and is different than the value read from the MATE the user can adjust the reading to match the meas
7. default of 1 hour Once the hour is up the FX will go into Silent mode essentially not charging Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 22 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 BATTERY CHARGING INSTRUCTIONS Keeping your battery bank healthy is very important Although a battery bank may last for over 10 years if properly cared for it can also be ruined in less than a month if neglected Since the batteries are the lifeblood of the system and represent a large percentage of the cost to the consumer keeping them healthy is necessary Battery Charging Set Points In order to make sure the batteries stay healthy they must never be discharged too much and should be regularly charged back to near full capacity Full capacity is only achieved by equalizing the batteries Check with the battery manufacturer to see how often your batteries should be equalized It is necessary for the system operator to gather some information from the battery manufacturer This information should include the following The Absorb Voltage The Float Voltage The Equalize Voltage The Recommended Depth of Discharge DOD of the batteries These Absorb Float and Equalize voltage set points should be programmed into the FX through the MATE see page 46 Programmin
8. 2 O o x 2 AC NEUTRAL OUT CHASSIS GROUND CHASSIS GROUND AC NEUTRAL IN INVERTER Control Wiring Terminal Block The AC terminal block in the AC wiring compartment is designed to accept up to 6 AWG 13 3mm wires A typica nidtanauun wii ude 8 AWG 8 35mm THHN type wire 8 AWG 8 35mm is reguired in order to handle the Export model s maximum input current of 30 amps All AC wiring connected to the AC terminal block must be rated for at least 75 C Torque all of the set screws on the AC terminal block to 30 inch pounds eguivalent to 2 5 foot pounds or 3 4 Nm The AC input should be supplied to the FX through a 30 amp maximum AC branch rated circuit breaker The AC hot input conductor black should be connected to the AC HOT IN terminal The AC neutral input conductor white may be connected to the AC NEUTRAL IN terminal or a common Neutral bus The AC NEUTRAL OUT terminal is common with the AC NEUTRAL IN terminal within the FX and only one AC neutral connection is required to be connected to the FX if a separate AC neutral bus is installed The other three terminals of the AC terminal block are for AC output wiring The AC HOT OUT terminal is to be connected to the AC loads through branch rated AC circuit breakers Many installations will use the OutBack AC IOB 30 input output bypass breaker assembly mounted in the OutBack PSAC or PS2AC This bypass assembly allows the user to completely bypass the FX While in the bypass
9. INPUT VOLTAGE An example of the menu structure is shown to the right All the screens that show AC meters are grouped together in one menu tree allowing the user to LEN find the required meter with a minimum of button presses The top line of the MATE display will show the path to the current menu in this example it is STATUS FX METERS STATUS FX METERS output 230 vac voltage DOWN UP TOP PORT Mate Buttons op Padel yar 2 patois Top Line SETUP FX INPUT P00 zm Line ac transfer GEN control rd DOWN GRID GI RT 3 Line Bottom Line The MATE uses a six button user interface to navigate the menus and to change set points of various OutBack products Two buttons are dedicated to the FX and are labeled AC IN and INV These buttons are special in that they can be pressed at any time anywhere in the MATE menu structure and they take you to the same screens For this reason they are referred to as hot keys Many common functions that need to be accessed often are found under the AC IN and INV button The four lower buttons under the LCD are called soft keys and are used for navigating around the menus and changing values Each soft key has various functions dependent on the label directly above it on the lower line of the LCD The top line on the MATE usually displays the path or location of where you are in the menu system The 2 and 3 lines of the MATE usual
10. P00 search 6 sensitivity DOWN INC DEC PORT SETUP FX SEARCH P00 The SEARCH PULSE LENGTH setting determines the number of pulses produced by the inverter search 8 cycles in quick succession actually AC cycles which are used to detect the level of the AC load pulse length connected Some AC loads do not draw much power from a single AC pulse setting this value to DOWN INC DEC PORT 8 or more pulses may allow the AC load to be detected more reliably This setting has a range between 4 cycles and 20 cycles in 1 cycle increments SETUP FX SEARCH P00 The SEARCH PULSE SPACING is the amount of time in number of AC cycles that the inverter search 60 cycles waits before producing additional AC pulses to sense a load The larger this search pulse spacing pulse spacing number is the lower the power consumption of the FX but the more noticeable the delay between DOWN INC DEC PORT when the AC load is turned on and when it actually comes on This setting has a range between 4 cycles and 120 cycles 2 seconds in 1 cycle increments SETUP FX SEARCH Selecting TOP returns the user to the top of the SETUP FX SEARCH menu section Selecting search setup SETUP returns you to the setup screen to allow selection of another product connected to the completed MATE Selecting MAIN returns the display to the MAIN screen TOP SETUP MAIN Installation amp P
11. DECLARATION OF CONFORMITY EU Declaration of Conformity According to ISO IEC Guide 22 and EN 45014 Product Type Power Inverter Charger Product Model Numbers FX2012E VFX2612E FX2024E VFX3024E FX2348E VFX3048E These products comply with the following EU directives Electromagnetic Compatibility 89 336 EEC Council Directive of 3 May 1989 On the approximation of the laws of member States relating to Electromagnetic compatibility Low Voltage Directive 73 23 EEC Council Directive of 19 February 1973 on the harmonization of the laws of Member States relating to electrical equipment for use within certain voltage limits The compliance of the above mentioned products with the directives and the following essential requirements is hereby confirmed when installed off grid Emissions and Immunity Safety EN 61000 3 2 2000 EN 60950 1 2002 EN 61000 6 3 2001 EN 61000 6 1 2001 EN 61000 3 3 1995 All associated technical files are located in the Engineering Department at OutBack Power Systems Inc Arlington Washington USA As the manufacturer we declare under our sole responsibility that the above mentioned product complies with the above named directives Robin Gudgel Arlington WA USA 03 August 2003 President Place and Date Cut Bock Power Systems 19009 62 Ave NE Arlington WA 98223 USA Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Prog
12. the maximum AC output fault current will be determined by the AC source NOMINAL DC VOLTAGE OUTPUT The last two digits in the model number designate the nominal DC voltage Example FX2324ET 24V DC Voltage MAXIMUM OVERCURRENT PROTECTION AMPACITY EXPORT AMPACITY DC BREAKER DC FUSE FX2012ET 250 amps OBDC 250 SMF 250 FX2024ET 175 amps OBDC 175 SMF 175 FX2348ET 100 amps OBDC 100 SMF 100 VFX2612E 250 amps OBDC 250 SMF 250 VFX3024E 175 amps OBDC 175 SMF 175 VFX3048E 175 amps OBDC 175 SMF 175 OBDC are panel mount circuit breakers SMF are DC terminal mounted fuses and should always be used in conjuncture with a disconnect FX s used in home installations should use properly sized DC breakers A DC breaker includes both overcurrent protection and disconnect capability SMF fuses are used primarily for marine installations where a DC disconnect is not required Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 9 MOUNTING All OutBack FX s can be mounted in any position Better performance will be achieved if it is mounted in a location which allows for air to circulate around the exterior of the casting Locating the FX in a cool location will improve the operation and ensure the highest efficiency and power capacity The following drawing provides the
13. 30 AMP OUTPUT llgypass 5 5 S BREAKERS OUTPUT INPU AC IN elele elele elele 36 SLAVE HREE CBI 30 AMP AC OUT INPUT BREAKERS TET NEUTRAL m k AC HOT IN L1 Cute 90 AMPS AC IN MAX a AC HOT IN Le K 3 Taa P H A S E AC HOT IN L3 AC SOURC 230 400 VAC 30 400 AR NEUTRAL AC BOX DC ALL BREAKERS SHOWN 3 PHASE 0A MAX 3 POLE Va FX BYPASS MECHANISM 2 ee 904 BYPASS S AND TERMINAL LOADS p BY Dr ee ee BLOCKS ARE HOUSED IN 400 VAL 24V 1754 BR 4Vi 1754 BRKRS Me gt 304 F ma o 24Vi 175A BRKRS THE OUTBACK PSAC output IB S e 48V 100A BRKRS 48V 1754 BRKRS BREAKERS e L2 3 PHASE goa Maa aoa FX gape 009 62nc ey 9 3 304 Ame ooo 19009 62nd AVE NE AC SOURCE INPUT ea Z femme BATTERS ARLINGTON WA 98223 230 400 VAC BREAKERS 360 435 6030 g 3 VFX3024E 3 VFX3048E 8 12KW 90A BYPASS PAR Program the top FX as Master 3PH MASTER and the two lower FX s as 3 phase Slaves 3PH SLAVE NOTES The AC OUTPUT NEUTRAL IS NOT BONDED TO THE CHASSIS OR THE GROUND TERMINAL of the FX system This connection is to be made by the installer either in the AC service entrance or within the AC load distribution panel of the electrical system The AC input AC output and DC terminals are isolated from the metal chassis of the FX Proper grounding of these circuits and the chassis of the FX is the responsibility of the installer Copyright 2003 OutBack Power Systems Inc FX amp VFX E S
14. GENERAL PRECAUTIONS 1 Before using the FX read all instructions and cautionary markings on 1 the FX 2 the batteries and 3 all appropriate sections of this installation and operation manual 2 CAUTION To reduce risk of injury charge only deep cycle lead acid lead antimony lead calcium gel cell or absorbed glass mat type rechargeable batteries Other types of batteries may burst causing personal injury and damage 3 The FX is approved for indoor mounting only in any position 4 Do not disassemble the FX Refer servicing to a qualified service center when service or repair is required Incorrect re assembly may result in a risk of electric shock or fire 5 To reduce risk of electric shock disconnect all wiring before attempting any maintenance or cleaning Turning off the FX may not reduce this risk Solar modules may produce hazardous voltages when exposed to light cover them with opaque material before servicing any connected equipment 6 WARNING WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION Provide ventilation to outdoors from the battery compartment The battery enclosure should be designed to prevent accumulation and concentration of hydrogen gas in pockets at the top of the enclosure Vent the battery compartment from the highest point A sloped lid can also be used to direct the flow of hydrogen to the vent opening at the highest possible lo
15. Installation amp Programming M anual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 17 FX SYSTEM CONFIGURATION SINGLE FX SYSTEM The FX System Configuration section shows diagrams of some typical system configurations using the Export FX There are diagrams for a single FX two FX s in parallel four FX s in parallel and a 3 phase system The diagrams show the proper breakers and wiring for the AC side of the installations as well as connections to the HUB or MATE Also included is information on the maximum continuous power of the systems and proper DC breaker sizes This information is dependent on whether the FX s are sealed or vented and on the system s battery voltage Single FX System The following diagram illustrates a typical single FX installation For this type of installation use of OutBack Power Systems PS2 system is recommended The bypass kit for the PS2 system is an AC IOB 30 using two CBI breakers with a bypass mechanism Please specify CBI breakers when ordering this bypass kit The single FX system will require an additional CBI 30 amp breaker for the AC input Additional breakers can be purchased and installed in the PS2AC if necessary All AC wiring must handle a capacity of 30 amps AC or more A single FX system can continuously power 2 3KW of loads depending on which model is used Connecting more power than the continuous rating of the FX may cause breakers
16. Inverter AC input Charger Aux and EQ METER Provides the AC voltages and currents of the FX BATT Provides the battery voltage and charger set points and timers lt PG2 gt Displays additional sections ERRORS WARNINGS and PG3 PG1 Returns to page 1 of the STATUS section ERROR Displays the different causes for errors and qualifies each cause with a Yes or No WARN Displays the different causes for warnings and qualifies each with a Yes or No lt PG3 gt Displays additional sections reason for last DISCONNECT and SELL PG2 Displays additional sections ERRORS WARNINGS and PG3 lt DISCON gt Displays the reason that the FX last disconnected from the AC source SELL Displays the code related to the reason for the last disconnection while selling MAIN Returns the user to the MAIN menu The ACIN FREQ TOO HIGH screen displays a Yes if the FX gets disconnected from the AC source due to the frequency of the AC source exceeding 59 Hz The MATE does not display the frequency of the AC source but this can be verified using an oscilloscope If this message occurs and the AC source is a generator it may be possible to adjust the frequency of the generator The ACIN FREQ TOO LOW screen displays a Yes if the FX disconnected from the AC source due to the frequency of the AC source being below 41 Hz The MATE does not display the frequency of the AC source but this can be verified using an oscilloscope If this message occurs and the AC source
17. Pressing the lt ON gt button will change the screen into MAN ON and the generator will turn ON To put this screen in AUTO mode you must access the AGS SETUP menu See your MATE manual for details CHARGER CONTROL Pressing the AC IN key a third time brings up the CHARGER CONTROL screen This allows Current ne AUTO operation of the battery charger to be preset for when an AC source is available In AUTO mode the charger will start charging when an AC source connects to the FX or when the FX OFF AUTO OK decides the batteries need charging In OFF mode the charger stays off but the AC source is still passed through to the loads Pressing the AC IN key a fourth time brings up the CHARGER MODE CONTROL screen This CHARGER ME ONE screen allows the MATE to issue system wide global charger commands Both OutBack MX Green Charges Mode and FX products will respond to global charger commands if they are connected together s through the HUB BULK EQ OK Pressing lt BULK gt brings up the BULK CONTROL screen it will allow the user to start and or BULK CONTROL stop a bulk charge cycle manually by pressing lt START gt or lt STOP gt respectively Pressing lt EQ gt brings up the EQUALIZE CONTROL screen START STOP OK When lt START gt has been selected two informational screens are displayed The user then must answer lt YES gt before an equalize charging cycle is allowed to begin Once the eq
18. and provides no charge to the battery This setting has a range between 0 hours and 24 hours in 0 1 hour increments ADV FX CHARGER P00 The REFLOAT SET POINT voltage is used to trigger the battery charger back into another FLOAT refloat 12 5 vade Cycle when the battery voltage falls to this set point This can provide maintenance charging of setpoint batteries and is also useful when intermittent DC loads are operated from a battery system and an AC DOWN INC DEC PORT source is available This setting has a range between 12 0 vdc and 13 0 vdc in 0 1 vdc increments ADV FX CHARGER P00 The EQUALIZE SET POINT voltage can be set for a high voltage to de stratify the batteries on equalize 14 4 vde occasion The user can start an equalization charge through the AC IN hot key The batteries must setpoint be supervised throughout the equalization process Consult the battery supplier as to specific DOWN INC DEC PORT instruction on the battery equalizing process This setting has a range between 14 0 vdc and 17 0 vdc in 0 1 vdc increments ADV FX CHARGER P00 The EQUALIZE TIME PERIOD can be adjusted to limit the amount of time that the battery is equalize 01 0 hrs equalized The timer starts to advance once the battery voltage exceeds the absorb voltage set point time period Once the timer reaches the equalize time period the charger goes into the silent stage of the charging DOWN INC DEC PORT process This setting ha
19. followed by a Yes it is possible that the AC source shut itself down this is sometimes the case with smaller generators or generators with an internal temperature shutdown switch MAIN 6 54 42P SUM STATUS SETUP ADV STATUS choose product FX MX STATUS FX PAGE1 choose category MODES METER BATT PG2 STATUS FX PAGE2 choose category PGl ERROR WARN PG3 STATUS FX PAGE3 choose category PG2 DISCON SELL MAIN STATUS FX DISCON P00 acin freg No too high DOWN STATUS PORT STATUS FX DISCON P00 acin freg No too low DOWN UP TOP PORT STATUS FX DISCON P00 acin voltage No gt max DOWN UP TOP PORT STATUS FX DISCON P00 acin voltage No lt min DOWN UP TOP PORT STATUS FX DISCON end of DISCON menu UP TOP STATUS Installation amp Programming Manual Page 40 The MAIN screen is where the menu system starts The four words in the bottom line of the display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two buttons simultaneously from anywhere in the menu will return you to this screen Allows selection of the product type lt FX gt FX inverter charger system MX MX60 PV MPPT charge controller MODES Status and allows adjustment of
20. maximum VFX E series 10 amps AC at 230 VAC maximum Note Factory settings are 4 amps AC for the Export version OPERATING FREQUENCY RANGE The FX will accept an AC source within the frequency range of 45 55 Hz Once the FX connects to the AC source if the frequency goes outside of the range 45 55 Hz the FX will record a warning If the frequency of the AC source is outside of the range of 41 59 Hz then the FX will drop the AC source NOMINAL AC OUTPUT VOLTAGE One FX will provide 230 VAC 50 Hz single phase Two or more FX s may be parallel stacked for 230 VAC 50 Hz single phase Three FX s can be 3 phase stacked for 230 400 VAC 50 Hz MAXIMUM AC OUTPUT CURRENT 35 amps Peak for 160 milliseconds current limit Inverter will shut down after 5 seconds of operation in current limit Installation amp Programming M anual FX amp VFX E Series Inverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 8 Rev 7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 RATINGS En MAXIMUM CONTINUOUS OUTPUT POWER Varies with model number of the inverter EXPORT VERSIONS FX2012ET 2000 VA FX2024ET 2000 VA FX2348ET 2300 VA VFX2612E 2600 VA VFX3024E 3000 VA VFX3048E 3000 VA MAXIMUM AC OUTPUT FAULT CURRENT The FX will go into fault if a sustained current draw of 25 amps RMS when operating as an inverter When passing an AC source through the FX via the AC transfer switch
21. me in port 1 of the hub 1 Classic Slave Not recommended for EXPORT FX s 2 OB Slave L1 In parallel with the master 3 OB Slave L2 Not recommended for EXPORT FX s 4 3PH Master I am the master in a 3 phase system Put me in port 1 of the HUB and switch the jumper in the HUB 5 3PH Slave 1st slave port 2 of hub 120 degrees out of phase of master 2nd slave port 3 of hub 120 degrees out of phase of first slave POWER SAVE LEVEL MASTER ADJ UST ONLY Read power save level slave adjust only first POWER SAVE LEVEL SLAVE ADJ UST ONLY In OutBack Stacking slave FX s can go to sleep turn off their outputs when the AC loads are low Sometimes half of the FX s need to be running because half of your appliances are on How does the master FX know how many slave FX s and which ones to turn on for the proper load All the slave FX s get assigned a rank from 1 to 7 If the master sees more than 5 amps AC of load it asks for help from the 1st ranking slave At this time because there are two FX s on the load for each FX will be about 2 5 amps AC The two FX s are sharing the load equally If the load increases and reaches 5 amps AC to the master 10 amps AC total the master will ask for help from the on ranking slave The 2 4 slave turns on and now 3 FX s are sharing the load about 3 5 amps AC each and about 10 amps AC total By ranking the slave FX s the master can control the flow of the system and keep idle power th
22. mounting and overall dimensions of the FX with the FXA kit DCC ACA DCA attached The first dimension is inches and the second value in parenthesis is the metric value in millimeters ACA 39 i 63 i l 6 T IH o f 9 NE T to pod ae k je ra 53 DCA Depth out from Wall Height up from Shelf 11 87 inches 301 mm 12 87 INCHES 327mm with Turbo installed For installations where the FX may be exposed to water spray either mount the FX with the base down shelf mounting or with the AC wiring compartment at the bottom wall mounting This will minimize the entry of water into the AC wiring compartment The FX ACA can be used to add an AC outlet and one or two of OutBack s AC rated OBDC circuit breakers up to 70 amps max When these items are added to the FX it should only be used in an area that is protected from rain AC Outlet or frir Tht l 4 Circuit Breakers l Side view of FX with FXA kit attached The Turbo Kit adds 1 25mm additional height to achieve a total height of 12 87 327mm Installation amp Programming M anual FX amp VFX E Series Inverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 10 Rev 7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 COMPLETE OUTBACK INTEGRATED SYSTEMS Shown below are complete systems of OutBack FX s for indoor
23. or for installations that can use a few hundred watts of extra power Typically the Turbo Kit adds 300 500 watts of power to the FX In hot climates or when the FX is the primary charging device the chances of the FX overheating are heightened When the FX gets to its temperature limits it will back off the charging process to avoid overheating and a shutdown of the FX The Turbo Kit solves this problem by directing air over the casting and its fins thus causing better convection for the FX The signal powering the Turbo Kit fan comes from the auxiliary output of the FX The default setting on the auxiliary output is set to CoolFan which starts the Turbo Kit automatically when the FX starts heating up The instructions for adding a Turbo Kit are included with the Turbo Kit If you are also automatically starting a generator using the auxiliary output you can program the auxiliary output to GenAlert and parallel the generator start wires with the Turbo Kit wires When the generator is running the Turbo Kit is also running This may seem like a poor solution but the FX gets hottest when it is charging If the paralleling of the generator and the Turbo Kit doesn t work properly adding a 470 uF micro Farad electrolytic capacitor found at your local electronics shop across the auxiliary output will solve this problem Out Back Power Systems Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System
24. or more All other AC wiring must handle a capacity of 30 amps AC or more This type of FX system can continuously power 6 9KW of loads depending on which model is used Connecting more power than the continuous rating of the FX may cause breakers to trip or the FX to shut off its AC output A HUB and a MATE must be connected to stack these FX s in 3 phase A MATE through the HUB if one is needed must be connected to adjust any parameters or to display any meters Once the FX has been programmed using the MATE the MATE can be disconnected The programming will be saved within the FX s non volatile memory even if the FX is completely shut down Three OutBack FX s can be stacked in a 3 phase configuration to power loads that require 3 phase power The diagram below represents 3 phase stacking of three FX s AC HOT OUT L1 AC HOT OUT L2 3 PHASE AC LOANS AC HOT DUT L3 Ac OUT K 230 400 YA NEUTRA 90 AMPS AC IND MAX K ejeje elele elele 26 sira s tag AC Our CBI 30 AMP TRIPLE NORMAL HL ala N A omg Go NI a vek EEG Add EEE VSE CBI
25. rating of the FX may cause breakers to trip or the FX to shut off its AC output A HUB and a MATE must be connected to stack these FX s in parallel A MATE through the HUB if one is needed must be connected to adjust any parameters or to display any meters Once the FX has been programmed using the MATE the MATE can be disconnected The programming will be saved within the FX s non volatile memory even if the FX is completely shut down The diagram below represents parallel stacking of two FX s AC HOT OUT AC LOADS 230VAC 60 AMPS nea MAX na rana NI CBI 30 AMP eo ee BYPASS WITH TWO CBI 30 AMP OUTPUT BREAKERS TJ Sg Ba 1m S Bu Ej zi 3 BP aA Ty zma lt ri Je el S 1 TWO CBI 30 AMP INPUT BREAKERS 60 AMPS MAX AC SOURCE 230VAC 22222 Da aba NEUTRAL AC BOX DC BOx 4 4 6KW 230VACIJ5 2 6KW 230VAC i Loa MANS PELE PARALLEL SEALED _ PARALLEL VENTED __ lpypass MECHANISM S AC KOAD Samm pon BYPASS Ez TeV 250A BRKRS OO levi 250A BRKRS AND TERMINAL 230VA0 Stl l e op PAV 175
26. source solar wind hydro etc This screen Battery 13 4V will only appear on Grid Tie FX s Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 34 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE STATUS MODES The STATUS screens allow the system user to check the operation of the FX system Both AC voltage and AC current meters are provided to enable monitoring adjustment and troubleshooting of the system operation The MODES section lets the user view and change the various modes for a specific FX by pressing the PORT to access a specific FX The modes include inverter ac in charger auxiliary and equalize The operation of these modes can be changed by selecting the CHANGE MODE option on the screen This is helpful if the user wishes to quickly enable or disable a particular function of a specific FX if necessary MAIN The MAIN screen is where the menu system starts The four words in the bottom line of the display 6 54 42P correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two buttons SUM STATUS SETUP ADV simultaneously from anywhere in the menu will return you to this screen STATUS Selecting lt STATUS gt allows selection of
27. the screen displays GridTie default the FX will sell power under the correct conditions authority Pressing DEC will change GridTie to No Sell and the selling function will be disabled DOWN INC DEC PORT Pressing INC will change the display back from No Sell to GridTie ADV FX SELL Selecting TOP returns the user to the top of the ADV FX SELL menu section Selecting ADV selling setup returns you to the advanced screen to allow selection of another product connected to the MATE completed Selecting MAIN returns the display to the MAIN screen TOP ADV MAIN Installation amp Programming Manual Page 52 FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE ADVANCED CALIBRATION The CAL calibration section is used in the factory or field to make fine adjustments in the operation of the FX It is particularly useful when multiple FX s are connected together in the different stacking configurations to maximize the performance of the FX s In most cases the user will not need to adjust these settings from the factory default values ADV FX PAGE1 choose category ADV INV CHGR PG2 ADV FX PAGE2 choose category PG1 GRID GEN PG3 ADV FX PAGE3 choose category PG2 AUX STACK PG4 ADV FX PAGE4
28. the symbol used to denote 500 watts or power per inverter is a dollar sign The fourth line of the summary screen provides information about the battery limited to battery voltage at this time To access the summary screen press the button under the label lt SUM gt from the MAIN screen Included below are some examples of different summary screens with an explanation of the information represented MAIN The MAIN screen is where the menu system starts The four words in the bottom line of the 6 54 42P display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing SUM STATUS SETUP ADV the left two buttons simultaneously from anywhere in the menu will return you to this screen DCEDAC 0 0kW To access the summary screen select SUM from the MAIN screen A typical summary screen AG BOBA 626 uv ee ee is shown here for a FX when the inverter is off and no AC source is connected No ACIN The BATTERY VOLTAGE is provided in the lower right corner of the display Battery 12 8V EXAMPLES DCEJAC gt gt gt 1 4kW INVERTING The FX is inverting and producing AC output voltage which is powering 1 4kW of AC Load mut AC loads No AC source is connected to the FX No ACIN Battery 12 1V DCE AC 0 0kW PASS THROUGH An AC source has been co
29. to a reason the FX would stop selling OutBack Power Systems technicians use this number to quickly understand what the FX thinks is happening The system user should not be concerned about this number unless they are experiencing many unknown grid disconnects and they need troubleshooting help This screen is only operational with Grid Tie FX s MAIN SEG FE 6 54 42P SUM STATUS SETUP ADV STATUS Se choose product FX MX STATUS FX PAGE1 choose category MODES METER BATT PG2 STATUS FX PAGE2 choose category PGl ERROR WARN PG3 STATUS FX PAGE3 choose category PG2 DISCON SELL MAIN The MAIN screen is where the menu system starts The four words in the bottom line of the display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two buttons simultaneously from anywhere in the menu will return you to this screen Allows selection of the product type lt FX gt FX inverter charger system MX MX60 PV MPPT charge controller MODES Status and allows adjustment of Inverter AC input Charger Aux and EQ METER Provides the AC voltages and currents of the FX BATT Provides the battery voltage and charger set points and timers lt PG2 gt Displays additional sections ERRORS WARN
30. until it is above this value This setting has a range between 80 vac and 220 vac in 2 vac increments The AC1 GRID UPPER LIMIT set point allows adjustment of the maximum voltage that the AC source is allowed to be in order for the FX to connect to that source If the AC source exceeds this value the FX will disconnect from the AC source until it is below this value This setting has a range between 250 vac and 300 vac in 2 vac increments The AC1 GRID INPUT LIMIT sets the maximum amount of current the FX allows to be drawn from the AC source When the AC input current limit is reached the power draw of the battery charger is backed off to prevent overloading the AC source If the AC loads exceed this limit the FX will give a warning and start blinking the red ERROR LED This setting has a range between 2 5 aac and 30 0 aac in 0 5 aac increments The AC1 GRID TRANSFER DELAY is the amount of time that the AC input will remain connected to the AC source when the AC input voltage drops below the AC1 GRID LOWER LIMIT setting Once the AC voltage has risen above the AC1 GRID LOWER LIMIT setting for the AC INPUT CONNECT DELAY time period the AC source will be reconnected This setting has a range between 0 cycles and 240 cycles in 1 cycle increments Selecting TOP returns the user to the top of the ADV FX GRID menu section Selecting ADV returns you to the advanced screen to allow selection of another product connected to the MATE Selecting MAIN ret
31. you will use the increment INC or decrement DEC buttons For example for a 12V FX the increment value is 0 1V A 24V FX has an incremental value of 0 2V and a 48V FX has an incremental value of 0 4V All values displayed in the Setup and Advanced menus are the default values unless otherwise stated For M versions of the MATE example MATE 2 M only the Status and Advanced menus are the same as non M versions of the MATE If you are using an M version of the MATE please consult the MATE manual for proper navigation and screen information Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 27 MATE SYSTEM CONTROLLER AND DISPLAY This section of the manual will cover how to use the buttons on the MATE to navigate the menus NOTE The menu system displayed on the MATE will vary depending on the software version that the MATE was programmed with at the time of manufacturing or during its last software upgrade Menu Structure MAIN MENU STATUS The OutBack MATE uses a branching menu structure to display various SETUP OutBack products operation modes and status The menus are divided by product type and are categorized by type of setting or by information being rene OUTPUT displayed VOLTAGE
32. 19009 62nd Ave NE Arlington WA 98223 USA Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 57
33. 4 BRKRS BAV 175A BRKRS BLES AE ausen am 2 304 1 m mi x C S2AC Gen 48V 100A BRKRS 48V 175A BRKRS 72 BREAKERS i FX CIm achk tp gt 20 2 Oz pe ih m lay 4KW 2 FXe012E 2 FX2024E ower Systems AC SOURCE koa MAX lt e gt 30A e TERY SKV 2 FX2348E 19009 62nd AVE NE 230VAC pe rn ES 52KW gt VEX2612E A ee yA 98223 EAK 6KW 2 VFXS024E 2 VFX3048E 4 6kw 60A BYPASS BAR Program the top FX as Master 1 2PH MASTER and the lower FX as an OutBack L1 Slave OB SLAVE L1 NOTES The AC OUTPUT NEUTRAL IS NOT BONDED TO THE CHASSIS OR THE GROUND TERMINAL of the FX system This connection is to be made by the installer either in the AC service entrance or within the AC load distribution panel of the electrical system The AC input AC output and DC terminals are isolated from the metal chassis of the FX Proper grounding of these circuits and the chassis of the FX is the responsibility of the installer Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 19 FX SYSTEM CONFIGURATION PARALLELED QUAD FX SYSTEM Paralleled Quad FX System The following diagram illustrates a typical paralleled FX installation using four FX s For this type of installation use of OutBack Power Syste
34. 98223 USA Page 56 REGISTRATION SSS ny Your purchase of an OutBack Power Systems product is an important investment Registering your products will help us maintain the standard of excellence you expect from us in terms of performance quality and reliability Please take a moment to register and provide us with some important information Name Address City State Zip Code Country Telephone Number E mail Sold by Installer Purchase Date Model Number Serial Number Circle all that apply Off Grid Installation Residential Installation North America Location Utility Connected Installation Commercial Installation Other EXTENDED WARRANTY APPLICATION OutBack Power Systems offers an optional three year extension to the standard two year limited warranty Purchase of extended warranty coverage is available on products listed below provided conditions shown are met Extended warranty coverage must be purchased within 90 days of the original sale of the product covered PRODUCT REQUIRED SURGE PROTECTION EXTENDED WARRANTY COST Any FX Series Inverter Charger AC Input AC Output DC Input 300 00 MX60 DC Input DC Output 100 00 MATE NA 50 00 HUB 4 NA 35 00 HUB 10 NA 50 00 Product Covered Serial Number Quantity Extended Warranty Cost Total Send check or money order payable to OutBack Power Systems Include a completed copy of this application and send to OutBack Power Systems Extended Warranty Program
35. A 98223 USA Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE STATUS WARNINGS The WARNINGS section of the STATUS menu allows the user to check the cause of a warning condition for the FX When a warning condition has occurred the red ERROR LED indicator in the FX s wiring compartment will flash The cause of the warning will not be immediately displayed on the MATE like an ERROR will Instead you must access this WARNINGS menu and scroll down the list to find out which warning is present This is indicated by the presence of a YES next to the appropriate cause listed Once the warning has been cleared the display will change back to NO as shown below and the red LED will stop flashing A warning will not shut the FX down like an error will STATUS FX PAGE2 choose category PGl ERROR WARN PG3 STATUS FX WARN P00 acin freq No too high DOWN STATUS PORT STATUS FX WARN P00 acin freg No too low DOWN UP TOP PORT STATUS FX WARN P00 acin voltage No too high DOWN UP TOP PORT STATUS FX WARN P00 acin voltage No too low DOWN UP TOP PORT STATUS FX WARN P00 ac input No current exceeds max DOWN UP TOP PORT STATUS FX WARN P00 temperature No sensor fault DOWN UP TOP PORT STATUS FX WARN P00 internal comm No error detected DOWN UP TOP PORT STATUS FX WARN P00 internal fan No failure detected DOWN UP TOP PORT
36. A 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 7 RATINGS ee JE i JJ JJ JP Ti 2277 MAXIMUM SYSTEM AC VOLTAGE Single phase 230 VAC at 50 Hz Parallel stacked 230 VAC at 50 Hz per AC output leg Three Phase 230 VAC at 50 Hz per AC output leg limit three 400 VAC at 50 Hz between AC output legs RECOMMENDED DC VOLTAGE RANGE 12V systems 11 16 VDC 24V Systems 22 32 VDC 48V Systems 44 64 VDC MAXIMUM DC INPUT CURRENT 12V units 600 amps 24 V units 300 amps 48V units 150 amps This is the most sustained current the FX will draw when starting very large AC loads It is not used for sizing the DC disconnect or selecting DC cable gauge It is used to select the minimum reasonable battery capacity AC INPUT OPERATING VOLTAGE RANGE 200 260 VAC Voltages outside of this range may damage AC loads connected to the FX s AC output MAXIMUM AC INPUT CURRENT 30 amps at 230 VAC 50 Hz The AC input on the FX supplies power for two separate internal AC circuits the AC transfer switch and the battery charging system The battery charger will back off when the combined total of the AC load and the battery charger exceed the programmed AC input current limit The FX s default setting for this parameter is 24 amps RECOMMENDED MAXIMUM AC PASS THROUGH CURRENT 30 amps at 230 VAC 50 Hz for each FX MAXIMUM AC CURRENT FOR AC BATTERY CHARGER FX E series 7 amps AC at 230 VAC
37. AL of the FX system This connection is to be made by the installer either in the AC service entrance or within the AC load distribution panel of the electrical system The AC input AC output and DC terminals are isolated from the metal chassis of the FX Proper grounding of these circuits and the chassis of the FX is the responsibility of the installer Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 1 8 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 FX SYSTEM CONFIGURATION PARALLELED DUAL FX SYSTEM Paralleled Dual FX System The following diagram illustrates a typical paralleled FX installation using two FX s For this type of installation use of OutBack Power Systems PS2 system is recommended The bypass kit for the PS2 system with two FX s is an AC IOB 30D using four CBI breakers with a bypass mechanism Please specify CBI breakers when ordering this bypass kit The dual FX system will require two additional CBI 30 amp breakers for the AC input Additional breakers can be purchased and installed in the PS2AC if necessary The AC wiring from the AC source and to the AC loads must handle 60 amps AC or more All other AC wiring must handle a capacity of 30 amps AC or more This type of FX system can continuously power 4 6KW of loads depending on which model is used Connecting more power than the continuous
38. Back MATE includes an INV hot key to allow direct control of the inverter from anywhere in the menu system The INV key is located on the right side of the MATE LCD display Pressing the INV key takes you to the INVERTER CONTROL menu shown below A green LED indicator is located above the INV key which flashes when the inverter is either in the search or power save modes and is on continuously when full AC output voltage is available from the FX When the inverter is turned off the green LED will not be illuminated ei Page 30 INVERTER CONTROL Pressing the INV key once brings up the INVERTER CONTROL screen To turn the inverter currently ON ON press the key located below the word lt ON gt Selecting lt SRCH gt will cause the inverter to begin operating in the search mode as long as the AC load connected is smaller than allowed by OFF SRCH ON OK the programming of the search function Selecting lt OFF gt turns off the inverters AC output signal Select lt OK gt to return to the point in the menu system from where you entered the INVERTER CONTROL screen Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Rev 7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE AC INPUT CONTROL CC IN SJ Sel lina 4 Battery Good t 24 SU AC Input Control The OutBack MATE incl
39. DCC covers the DC terminal area and allows a space which can be used to mount other components such as a DC current shunt The FX DCC can be used with or without the FX DCA When installing an FX with a PSDC or PS2DC disconnect enclosure both the FX DCA and FX DCC are required FXA ACCESSORY KIT The FXA includes all three of these FX accessories in one box Out Back Power Systems Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming M anual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 15 HUB COMMUNICATION MANAGER The HUB communication manager allows the MATE to control and monitor a maximum of ten OutBack products Currently the HUB comes in two types The HUB 4 can connect up to four Outback FX s MX 60 MPPT charge controllers or a combination of the two The HUB 10 shown below can connect up to ten Outback FX s MX 60 MPPT charge controllers or a combination of the two The FX s can be operated in a stacked or independent configuration If the FX s are to be stacked the HUB must be part of the system In a stacked configuration the Master FX must be plugged into port 1 of the HUB The Slave inverters must use the following ports example for 8 inverters and 2 MX 60 s the Master must be plugged into Port 1 and the seven Slaves must be plugged into Ports 2 8 The MX 60 s can use Ports 9 a
40. IMETERS 14 3 14 0032 2 08 078 1 98 12 1 98 0051 3 31 101 2 57 10 1 24 0082 5 26 126 3 20 8 0 78 0130 8 37 162 4 11 6 0 50 0206 13 30 215 5 46 4 0 31 0328 21 15 269 6 83 2 0 19 0521 33 62 337 8 56 1 0 15 0657 42 41 376 9 55 1 0 0 12 0829 53 50 423 10 74 2 0 0 10 1045 67 43 508 12 90 3 0 0 08 1318 85 01 576 14 63 4 0 0 06 1662 107 20 645 16 38 Installation amp Programming Manual Page 54 FX amp VFX E Series I nverter C harger System Rev7 0 07 02 04 Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 WARRANTY OutBack Power Systems Two Year Limited Warranty OutBack Power Systems Inc warrants that the products it manufactures will be free from defects in materials and workmanship for a period of two 2 years subject to the conditions set forth below The limited warranty is extended to the original user and is transferable The limited warranty term begins on the date of invoice to the original user of the product The limited warranty does not apply to any product or part thereof damaged by a alteration or disassembly b accident or abuse c corrosion d lightning e reverse polarity f repair or service provided by an unauthorized repair facility g operation or installation contrary to instructions pertaining to the product OutBack Power Systems liability for any defective product or any part thereof shall be limited to th
41. INC DEC PORT ADV FX GRID POO acl grid 208 vac lower limit DOWN INC DEC PORT ADV FX GRID POO acl grid 270 vac upper limit DOWN INC DEC PORT ADV FX GRID POO acl grid 24 0 aac input limit DOWN INC DEC PORT ADV FX GRID POO acl grid 6 cycles transfer delay DOWN INC DEC PORT ADV FX GRID GRID programming completed TOP ADV MAIN Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Once the password has been correctly entered the ADV CHOOSE PRODUCT is displayed Selecting lt FX gt allows adjustment of the FX s advanced programming Selecting lt PG2 gt advances the user to the second page of the advanced menu Selecting lt GRID gt allows adjustment of the AC input set points and operation The AC INPUT CONNECT DELAY set point adjusts the time period of when the FX sees an acceptable AC source to when it connects the AC loads to that source This is useful to allow the utility grid to become stable after a utility power outage This setting has a range between 0 2 minutes to 15 minutes in 0 1 minute increments The AC1 GRID LOWER LIMIT set point allows adjustment of the minimum voltage that the AC source is allowed to be in order for the FX to connect to that source The FX will back off the charger if the AC source is at this lower limit If the AC source falls below this limit the FX will disconnect from the AC source
42. INGS and PG3 PG1 Returns to page 1 of the STATUS section ERROR Displays the different causes for errors and gualifies each cause with a Yes or No WARN Displays the different causes for warnings and gualifies each with a Yes or No lt P G3 gt Displays additional sections reason for last DISCONNECT and SELL PG2 Displays additional sections ERRORS WARNINGS and PG3 DISCON Displays the reason that the FX last disconnected from the AC source lt SELL gt Displays the code related to the reason for the last disconnection while selling MAIN Returns the user to the MAIN menu STATUS FX SELL P00 The STOP SELL REASON displays a numerical value that indicates a reason that the FX stopped stop sell 14 selling to the utility grid It could indicate that the utility grid s voltage or frequency is out of the reason acceptable ranges or that the utility grid failed altogether This screen is used for troubleshooting by STATUS PORT OutBack Power Systems technicians Selecting STATUS returns the user to the beginning of the STATUS menu Selecting PORT selects the next FX on the HUB Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 41 MATE SETUP SEARCH The OutBack FX includes a SETUP menu to allow limited adjustment of some of the settings which may need to be acce
43. LAY eoreseevsvrevserevnerenseneenensenennennenennennenennensenennennenennennenennennenennenennannensenennensenennenneneer 26 MATE INVERTER CONTROL oriin ara E E E N NN N 30 MATE AC INPUT CONTRO LvtessscsvcssescsnscssovsuconssosncsssscsvecsescsussdeevedseneseskesdeseDveuuesconsesesssugexescskesilesssuestensenesisesshgexesdskgesesedveeuessousssssess 31 IMATE MENU MAP sinovo jv eve oka ije pie asses ddendesesccsdedsocontesedtes kaki ia kake aken aa ae Vaba dedsoventesnsuse seen 32 MATE SUMMARY SCREEN nonor initiat N NAAA A EAS EAS NAAA N 34 MATE STATUS skannere 35 MATE SETUP wissccssstsssesseessccsecteveestorss soj ooo ih GE S AEEA ERED zj itk ne aaea E no boji ah vo oda a a 42 MATE ADVANCED inais innritan kaja E AEEA kaj oka oo etiko nd ni o aja ob kot ajno bajno vedejo agnet 44 WIRE SIZES iiiaio Disi inti SNR E EEA E EASE T ESEA E ES NEA E EA 54 WARRANTY RI EAE EAA T EEA E OA EE AEEA V TE E ES 55 REGISTRATION renina R akade E EA S S AAA EASE TSE E E ERA SR nag nagerb esde 57 Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 3 Installation amp Programming M anual FX amp VFX E Series Inverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 4 Rev 7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019
44. OutBack Power Systems Export FX and VF X Inverter C harger Installation and Programming Manual Document Revision 7 0 FX 2012ET 2 0 kW 12 VDC 230 VAC 50 Hz Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 1 Rev 7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 Installation amp Programming M anual FX amp VFX E Series Inverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 2 Rev 7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 TABLE OF CONTENTS DECLARATION OF CONFORMITY isccsscesssessessssoonsssoseonsesoesonsesoseonsesesoonsesosessoesoedonsendsoossenesoonssiossonaesosdonosnonssnesoonaenssnesnssoesossonsendseses 5 IMPORTANT SAFETY INSTRUCTIONS wisccssccsssctsssotsesssecssosessonsensisetecsossobsensssctsosessoksensisossssossensssossosessensensheskessonssssensesonsineasesenasessees 6 RATINGS isti icesectsscoseossscspeososceseoasscosensvecoseoassconessosdesesnsssenessoncosseasssonessosdesoonossonasseesondendnesnesnendossvasasenasseecensunssdenosvesceaveneadensusssdennensasense 8 MOUNTING se civics coscetsstessarsscodsetsscosesiss cossersstosestescoseeesscosesees dod PODE RV OETA E A OE R A RAA AN 10 COMPLETE OUTBACK INTEGRATED SYSTEMS eesesversvrenserenversnnensensnnensensnnensensnnensensnnensensnnensensnnensnnensensenensensensnnensen
45. S FX PAGE1 choose category MODES METER BATT PG2 STATUS FX PAGE2 choose category PGl ERROR WARN PG3 STATUS FX ERROR P00 low ac output o voltage DOWN STATUS PORT STATUS FX ERROR P00 stacking o error detected DOWN UP TOP PORT STATUS FX ERROR P00 inverter o overtemp DOWN UP TOP PORT STATUS FX ERROR P00 low battery o voltage DOWN UP TOP PORT STATUS FX ERROR P00 phase loss o error DOWN UP TOP PORT STATUS FX ERROR P00 high battery o voltage DOWN UP TOP PORT STATUS FX ERROR P00 ac output o shorted DOWN UP TOP PORT STATUS FX ERROR P00 ac output o backfeed DOWN UP TOP PORT STATUS FX ERROR P00 nd of error menu UP TOP STATUS Installation amp Programming Manual Page 38 The MAIN screen is where the menu system starts The four words in the bottom line of the display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two buttons simultaneously from anywhere in the menu will return you to this screen Allows selection of the product type lt FX gt FX inverter charger system MX MX60 PV MPPT charge controller MODES Status and allows adjustment of Inverter AC input Charger Aux and EQ METER Provides the AC voltages and c
46. TE 2M 232 Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 26 Rev 7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE SYSTEM CONTROLLER AND DISPLAY OutBack MATE System Controller and Display Inverter AC Input LED Indicator LED Indicator green yellow Dedicated Dedicated AC Input Inverter Control Control HOT Key HOT Key Variable Soft Keys Each one of the soft keys corresponds to a word on the bottom line of the LCD display The menu system displayed on the MATE will vary depending on the software version that the MATE was programmed with at the time of manufacturing or during its last software upgrade For your particular menu system consult your MATE manual The following pages show the portion of the menu structure that relates to the FX Most of the menu will be consistent no matter what type of FX you have purchased The MATE displays that follow are from the most current MATE being sold by OutBack Power Systems The DC voltage values the letters vdc usually follow these values shown in the following MATE displays will be the default values for a 12V version of the Export FX For the 24V version multiply these values by 2 For the 48V version multiply these values by 4 This multiplication process includes the incremental values when changing a voltage setting
47. TER end of meter menu UP TOP STATUS Installation amp Programming Manual Page 36 MODES Shows status and allows adjustment of Inverter AC input Charger Aux and EQ lt METER gt Provides the AC voltages and currents of the FX BATT Provides the battery voltage and charger set points and timers PG2 Displays additional sections ERRORS WARNINGS and PG3 This screen shows the mode and where power is flowing within the FX The modes include Invert Charge Pass Through Support and Sell When the FX is in the Invert Support or Sell mode the inv 0 0kw meter will change When the FX is in the Charge mode the chg 0 0kw meter will change The zer 0 0kw will change to sel 0 0kw and show a change when the FX is in the Sell mode The buy 0 0kw meter will change when the FX is either in Pass Through or Charge mode The OUTPUT VOLTAGE meter indicates the AC voltage on the AC output of the FX which is available to power the AC loads When the inverter is in the SEARCH mode the AC output voltage may not be the nominal output of 230 VAC This is a normal condition Increasing the AC load or selecting ON from the INVERTER CONTROL menu screen will return the AC output voltage to normal The INPUT VOLTAGE meter indicates the AC voltage on the AC input of the FX system from an AC source such as utility grid or back up generator When the FX is connected to an AC source the input AC voltage will equal the output AC vol
48. TER inverter programming completed TOP ADV MAIN Copyright 2003 Tel 360 435 6030 Fax 360 435 6019 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Once the password has been correctly entered the ADV CHOOSE PRODUCT menu is displayed Selecting lt FX gt allows adjustment of the FX s advanced programming Selecting lt INV gt allows adjustment of the FX s inverter set points and operation The SEARCH SENSITIVITY setting determines how much AC load is required to make the FX switch from the search mode to the normal inverter on mode Increasing the number INC decreases the sensitivity more power must be turned on to bring the FX out of search while decreasing the number DEC increases the sensitivity less power must be turned on to bring the FX out of search Adjusting this setting to zero will effectively disable the search mode operation The SEARCH PULSE LENGTH setting determines the number of pulses produced by the inverter in quick succession actually AC cycles which are used to detect level of AC load connected Some AC loads do not draw much power from a single AC pulse setting this value to 8 or more pulses may allow the AC load to be detected more reliably This setting has a range between 4 cycles and 20 cycles in 1 cycle increments The SEARCH PULSE SPACING is the number of AC cycles that the inverter waits before producing add
49. Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 33 MATE SUMMARY SCREEN Summary Screen The OutBack MATE includes a SUMMARY screen to allow easy understanding of the FX operation The display uses both words and symbols to show what currently is happening in the system along with a limited amount of numbers This makes it easier for the system user to understand where the power is flowing within the system The first line of the summary screen displays DC AC and is measured in kilowatts kW This is to indicate the approximate AC power that is being both produced and consumed by all the FX s connected to the MATE multiple FX s can be connected to one MATE through the HUB Basically it shows how much work the FX s are doing and relates to energy being transferred between the FX s and the batteries The second line of the summary screen displays AC Load and has a light bulb symbol that appears for every 500 watts of power per FX that is being delivered to the AC loads so 1 light bulb equals 1kW when two FX s are used with a single MATE through the HUB The third line displays four different things depending of the status of the AC input It displays No ACIN when the FX doesn t sense an AC source present It displays AC Drop when an AC source is present but not connected It displays Buying when an AC source is connected and the FX is using the source to charge or pass through to the loads In the third line
50. a 2 wire type generator is possible and must be done through a 12 volt DC relay Time delays for ON and OFF are adjustable Using Advanced Generator Start AGS will override any AUX function that is programmed See the next page to adjust the set points for this function Selecting LOADSHED enables the AUX output to function as a load management system When the battery voltage drops below the LOAD DISCONNECT set point for more than 3 seconds the AUX output is energized Connecting a normally closed NC relay to the circuitry of non vital loads will disengage them with this function LOADSHED will also occur when the FX approaches an over temperature condition or when the AC output voltage drops below 202 vac for more than 3 seconds There is a 3 minute fixed delay before the AUX output is de energized See the next page to adjust the set points for this function Selecting REMOTE enables the AUX output to be controlled by the MATE or a PC computer connected to the MATE PC communication port This function is currently not operational It will be operational in the future Press lt DOWN gt after selecting the AUX OUTPUT FUNCTION of your choice The AUX menu section is continued on the following page FX amp VFX E Series Inverter C harger System Installation amp Programming Manual Rev 7 0 07 02 04 Page 49 MATE ADVANCED AUX OUTPUT SET POINTS This page contains to settings for the various functions that can be chosen in th
51. ain below the GENALERT ON SETPOINT voltage for the AUX output to become energized This setting is provided to allow for short periods of heavy load usage This setting has a range between 0 minutes and 240 minutes in 1 minute increments The GENALERT OFF SETPOINT is the battery voltage at which the AUX output is de energized when the AUX OUTPUT FUNCTION has been set to GENALERT This setting has a range between 12 0 vdc and 18 0 vdc in 0 1 vdc increments The GENALERT OFF DELAY set point is the amount of time that the battery voltage must remain above the GENALERT OFF SETPOINT voltage set point for the AUX output to become de energized This setting is provided to allow the battery charger to more fully recharge the battery once it has been started This setting has a range between 0 minutes and 240 minutes in 1 minute increments The LOADSHED OFF SETPOINT is the battery voltage at which the AUX output is energized to reduce the load on the inverter and battery system Once the battery voltage has dropped below this setting for 3 seconds the AUX output will have 12 vdc available to power a DC coil relay to disconnect an AC load Once the LOADSHED function has been triggered it will remain on for a minimum of 3 minutes This setting has a range between 10 0 vdc and 14 0 vdc in 0 1 vdc increments The VENTFAN ON SETPOINT is the battery voltage at which the AUX output is energized when the AUX OUTPUT FUNCTION has been set to VENTFAN The AUX output c
52. an be used to keep hydrogen from accumulating by exchanging the air in the battery enclosure This setting has a range between 10 0 vdc and 16 0 vdc in 0 1 vdc increments The VENTFAN OFF PERIOD set point can be used to allow for intermittent operation of the battery enclosure ventilation system Setting the time period to 5 minutes will operate the fan at a 50 duty cycle as the on time period is fixed at 5 minutes Setting the VENTFAN OFF PERIOD to zero will keep the fan on continuously when the battery voltage exceeds the VENTFAN ON voltage set point This setting has a range between 0 minutes and 30 minutes in 1 minute increments The DIVERSION ON SETPOINT enables the AUX output to function as a diversion controller This can be used to send excess power from a renewable energy source to a load This can allow control of sources such as wind turbines or hydro generators Two types of DIVERT are selectable DIVERTDC and DIVERTAC The only difference is that the AC diversion setting will quickly turn off the AUX output if the FX is overloaded This setting has a range between 12 0 vdc and 16 0 vdc in 0 1 vdc increments The DIVERSION OFF DELAY is the amount of time that the AUX output will continue to be energized after the battery voltage falls below the DIVERSION ON SETPOINT voltage In cases where the battery voltage is hovering around the DIVERSION ON SETPOINT voltage the AUX output won t flicker This setting has a range between 0 seconds
53. and 240 seconds in 1 second increments Selecting TOP returns the user to the top of the ADV FX AUX menu section Selecting ADV returns you to the advanced screen to allow selection of another product connected to the MATE Selecting MAIN returns the display to the MAIN screen FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE ADVANCED STACKING The STACK stacking section is used to program the stacking of the FX s as well as which Slave FX s will stay ON at all times won t go into Power Save mode and in what order the slave FX s will come ON if they are in Power Save mode An explanation of stacking can be found on page 23 of this manual ADV FX PAGE1 choose category ADV INV CHGR PG2 ADV FX PAGE2 choose category PG1 GRID GEN PG3 ADV FX PAGE3 choose category PG2 AUX STACK PG4 ADV FX STACK POO Stack 1 2ph Master phase DOWN INC DEC PORT ADV FX STACK POO power save level 0 master adjust only DOWN INC DEC PORT ADV FX STACK POO power save level slave adjust only DOWN INC DEC POR ADV FX STACK stacking setup completed TOP ADV MAIN Copyright 2003 OutBack Power Systems Inc Once the password has been corre
54. and INV is allowed from the advanced menu and selecting OK from these screens will return you to the same point in the advanced menu The password for the inverter is currently fixed to the same value for all of the FX s PASSWORD CODE 141 MAIN The MAIN screen is where the menu system starts The four words in the bottom line of the 6 54 42P display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two SUM STATUS SETUP ADV buttons simultaneously from anywhere in the menu will return you to this screen ADV SETTINGS WARNING Selecting lt ADV gt brings up a warning message Please read the message Pressing any of the changes made could four keys below the display advances the display to the password screen adversely effect system performance ADV PASSWORD Entering the correct password number is done by pressing the ANC gt key to increase the enter the password number or the lt DEC gt key to decrease the number Once the number shown matches the 132 password code press the key below the word lt ENTER gt To leave the advanced menu area ENTER INC DEC EXIT without making any changes press EXIT Following the password screen is a screen that allows selection of the OutBack product type Selecting lt FX gt allows adjustment of the FX s advanced progra
55. arger is backed off to prevent overloading the AC source If the AC loads exceed this limit the FX will give a warning and start blinking the red ERROR LED This setting has a range between 2 5 aac and 30 0 aac in 0 5 aac increments The AC2 GEN TRANSFER DELAY is the amount of time that the AC input will remain connected to the AC source when the AC input voltage drops below the AC1 GEN LOWER LIMIT setting Once the AC voltage has risen above the AC1 GEN LOWER LIMIT setting for the AC INPUT CONNECT DELAY time period the AC source will be reconnected This setting has a range between 0 cycles and 240cycles in 1 cycle increments The AC2 GEN SUPPORT setting allows the FX to assist the generator for very large AC loads or if the generator s continuous power is less than the continuous power of the FX and the loads are drawing more power than the generator can give For this feature to work properly the generator FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE ADVANCED AUX OUTPUT CONTROL amp FUNCTION The AUX auxiliary section can be used to control external AC or DC loads signal a generator start system send a fault alarm signal or to run a fan The AUX output provides a 12 vdc 0 7 adc output on the AUX terminals located in the AC wiring compartment
56. ase and decrease respectively SETUP FX INPUT P00 ac transfer GEN In this example pressing lt DOWN gt will take you to the next set point screen in control the SETUP FX INPUT menu DOWN GRID GEN PORT SETUP FX INPUT P00 Input setup completed TOP SETUP MAIN SETUP FX INPUT P00 ac transfer GEN control DOWN GRID GEN PORT SETUP FX INPUT P00 acl grid 24 0 aac limit DOWN INC DEC PORT ADV FX AUX aux output CoolFan function DOWN INC DEC PORT In this example pressing lt TOP gt will take you to the first screen in the SETUP FX INPUT menu lt SETUP gt will return you to the SETUP FX screen and lt MAIN gt will take you back to the Main screen In this example pressing lt GRID gt will change the FX AC transfer control to GRID mode Conversely pressing lt GEN gt will change the FX AC transfer control to GEN mode In this example pressing lt INC gt or lt DEC gt will change the numerical value of the ac1 grid limit setting In this example there are multiple operating modes for the aux output function Pressing lt INC gt or lt DEC gt will cycle through the available modes Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 29 MATE INVERTER CONTROL Inverter Control The Out
57. ates the selection used to advance the display to the next screen Pressing the left two buttons simultaneously from anywhere in the menu will return you to this screen Allows selection of the product type lt FX gt FX inverter charger system MATE MATE system display and user interface The categories are then displayed for the settings which can be adjusted in the setup menu SRCH Allows adjustment of the settings for the Search mode lt INPUT gt Allows selection of the AC INPUT and current limit adjustment MAIN Returns the display to the MAIN screen The AC TRANSFER CONTROL screen lets the user select the type of AC input which is connected to the FX This is used to choose the source of the AC input entering the FX The two choices are GRID for the utility grid or GEN for a generator The settings for the AC source are found in the advanced menu under the headings GRID and GEN see next page The AC1 GRID LIMIT is the maximum amount of current that the FX will allow to be drawn by AC loads and battery charger together from the utility grid When this limit is reached the charger will be backed off to keep from overloading the utility grid This setting has a range between 2 5 aac and 30 0 aac in 0 5 aac increments The AC2 GEN LIMIT is the maximum amount of current that the FX will allow to be drawn by AC loads and battery charger together from the generator When this limit is reached the charger will be backed off to kee
58. bsorb Time Limit must be long enough DOWN INC DEC PORT for the batteries to regain 100 of their charge ADV FX CHARGER P00 The ABSORB TIME LIMIT can be adjusted to provide enough time at the Absorb Setpoint to achieve absorb 01 0 hrs a fully recharged battery For large batteries a longer time may be required small batteries may time limit require a lower setting The FX automatically reduces the Absorb Time Limit when the charger is DOWN INC DEC PORT connected to a partially charged battery This setting has a range between 0 hours and 24 hours in 0 1 hour increments ADV FX CHARGER P00 The FLOAT SET POINT is the voltage that the batteries will be trickle charged to This charge will float 13 6 vde finish the charging process by putting the last few percentage points of charge into the batteries This setpoint set point can be adjusted to match the specific requirements of the batteries being charged This DOWN INC DEC PORT setting has a range between 12 0 vdc and 15 0 vdc in 0 1 vdc increments ADV FX CHARGER P00 The FLOAT TIME PERIOD can be adjusted to set the amount of time that the battery is held at the fi av 01 0 hrs Float Setpoint For large batteries a longer time may be required smaller batteries may use a lower time period setting Once the battery has been held at the Float Setpoint for the Float Time Period the battery DOWN INC DEC port Charger goes silent
59. cation NEVER charge a frozen battery 8 No terminals or lugs are required for hook up of the AC wiring AC wiring must be copper wire and rated for 75 C or higher Battery cables must be rated for 75 C or higher Crimped and sealed copper ring terminal lugs with a 5 16 3 8 8mm 10mm hole should be used to connect the battery cables to the DC terminals of this FX Soldered cable lugs are also acceptable 9 Torque all AC wiring connections to 30 inch pounds equivalent to 2 5 foot pounds or 3 4 Nm 10 Torque the DC connections to 60 inch pounds equivalent to 5 foot pounds or 6 8 Nm 11 Be careful with tools to reduce the risk of dropping metal objects onto batteries It may short circuit the batteries or other electrical parts resulting in fire or explosion ADDITIONAL NOTICES For instructions on mounting see the MOUNTING section of this manual For battery installation and maintenance read the battery manufacturer s instructions prior to installation and operation All installations must comply with local and national electrical codes and standards GROUNDING INSTRUCTIONS This FX should be connected to a grounded permanent wiring system For most installations the negative battery conductor should be bonded to the grounding system at one and only one point in the system All installations should comply with national and local codes and ordinances RONG PERSONAL PRECAUTIONS WHILE WORKING WITH BATTERIES 1 Someone should b
60. changes the mode between OFF AUTO and ON Selecting OFF disables the AUX output from operating Selecting AUTO allows the AUX output to automatically perform the function that is selected in the AUX OUTPUT FUNCTION screens below Selecting ON forces the AUX output to be kept ON regardless of the function selected Pressing lt DOWN gt allows the selection of the AUX OUTPUT FUNCTION There are nine functions in this section The default setting is Cool Fan which is set to run a Turbo Kit without any programming The function at the top of the menu is AC Drop The user must press lt INC gt three times in order to get to the top of the list of functions Selecting AC DROP enables the AUX output when the AC source that is connected to the FX ceases due to a power outage or a generator quitting This allows the user to attach an indicator to the AUX output to warn the user that the FX does not recognize that an AC source is available Selecting DIVERT enables the AUX output to function as a diversion controller This can be used to send excess power from a renewable energy source to a load This can allow control of sources such as wind turbines or hydro generators Two choices of DIVERT are provided DivertDC and DivertAC DivertDC is used to divert power to DC loads and DivertAC is used to divert power to AC loads The only difference is that the DivertAC setting will turn off the AUX output if the inverter
61. cting MORE displays a screen that allows the user to select which port on the HUB that the FX to be reset is on Once the user has chosen the PORT or if there is not a HUB the user should press NEXT to proceed To complete the reset to factory defaults the user must press 1 and then 2 Selecting TOP returns the user to the top of the ADV FX INVERTER menu section Selecting ADV returns you to the advanced screen to allow selection of another product connected to the MATE Selecting MAIN returns the display to the MAIN screen FX amp VFX E Series Inverter C harger System Installation amp Programming Manual Page 45 Rev 7 0 07 02 04 MATE ADVANCED CHARGER The CHARGER section allows for adjustment of the battery charger s operation to match the reguirements of the batteries used OutBack s default battery charging set points may not be correct for the type of batteries being used Please contact the battery manufacturer for correct ABSORB FLOAT and EOUALIZE voltages See the BATTERY CHARGING INSTRUCTIONS on page 23 for guidelines on how to set some of these values The FX s battery charger includes five stages BULK raises the battery voltage to the Absorb Setpoint ABSORB sustains the battery voltage for the Absorb Time Limit The charger then goes into SILENT mode no charging until the battery voltage drops to the Float Setpoint FLOAT sustains this battery voltage for the Float Time Period The charger then goe
62. ctly entered the ADV CHOOSE CATEGORY screen is displayed Selecting lt PG2 gt shows a second screen of categories Selecting lt PG3 gt shows a third screen of categories Selecting lt STAC K gt allows adjustment of the stacking set points and operation The STACK PHASE screen sets the hierarchy of the FX s If the system is to be stacked a HUB must be included and the FX that is to be the MASTER must be plugged into port 1 of the HUB The default for every FX is 1 2ph Master Pressing PORT will select the next port that an FX is plugged into When the port for the slave FX has been chosen press INC to cycle through the slave options Classic Slave OB Slave L1 OB Slave L2 3ph Master and 3ph Slave The POWER SAVE LEVEL MASTER ADJ UST is used to set the number of FX SLAVE s that will remain on under any load condition The value corresponds to the rank of the SLAVE For example setting this value to 2 allows all slaves with POWER SAVE LEVEL SLAVE ADJUST ONLY values 2 or less to stay on at all times Setting this number to a low value will result in fewer FX s remaining on and will provide the highest system efficiency The POWER SAVE LEVEL SLAVE AD UST is used to set a slave FX s priority for operation when the complete system is operating at medium to heavy loads By setting each of the slaves to a different number you can control the sequence that the slave FX s are turned on by the master FX Selecting TOP returns th
63. dditional components are designed to complete the installation to code while offering flexibility for future expansion 49 546 gl ifs Del zi Installation amp Programming M anual FX amp VFX E Series Inverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 1 1 Rev 7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 AC WIRING CONNECTIONS The FX system and the other OutBack balance of system components are designed to make it easy to meet any local and national electrical installation requirements When used outside of the USA follow the local installation codes for your country If you are not familiar with the local installation codes you should have the equipment installed by a qualified renewable energy equipment dealer or electrician All wiring methods are to be made in accordance with the local electric code I S i J BATTERY NATE AC NEUTRAL IN HUB STATUS TEMP FILTER Grounp BATTERY AC NEUTRAL our tl a S s z 5 S o a a w o The FX includes an AC wiring compartment with both a removable cover and AC conduit plate Depending on the type of installation the AC conduit plate may or may not be used OUTBACK POWER SYSTEMS SSS OOS Et MATE HUB Jack AC Terminal Block STATUS LED s MATE STATUS BATTERY TEMP Jack BATTERY BATTERY LED s AC HOT IN BATTERY
64. dvanced system operating modes such as the HIGH BATTERY TRANSFER HBX function or the ADVANCED GENERATOR START AGS function requires that a MATE be connected to the FX system all of the time The operating software used in the MATE is upgradeable to allow for the addition of new features to existing systems It can be easily removed and exchanged by the system user there is a single CAT5 RJ45 modular connection The MATE also includes an RS 232 PC serial communication port to allow monitoring and remote modem access of the system via phone or internet This PC software is currently being developed by third party companies and will soon be offered as an option through your OutBack Power Systems dealer Tracking software is available at www RightHandEng com OutBack Outback Power Systems currently offers five different versions of the MATE MATE Basic MATE with an oval encasing shown below The casing is white in color This option includes an RS 232 port MATE B Basic MATE with an oval encasing The casing is black in color This option includes an RS 232 port MATE 2 Black flush mount version of the MATE shown below This option includes an RS 232 port MATE 2M Black flush mount version with a simplified menu structure designed specifically for the Mobile market No RS 232 access MATE 2M 232 Same as MATE2M but with the RS 232 port accessible OutBack MATE System Controllers MATE MATE B MATE 2 MATE 2M MA
65. e so use some care Use a flat bladed screw driver blade in the slots provided on the sides of the battery terminal cover to pry the cap off If the installation is exposed DC conduit may be required Connection of 2 inch conduit is possible when the FX DCA and FX DCC options are added to the FX system ALWAYS install the Battery Terminal Covers even in systems that have an FX DCC included Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 14 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 FX ACCESSORIES FX ACA AC CONDUIT ADAPTER This plastic box slips into grooves on the AC end of the FX This adapter extends the AC wiring compartment to match the PSAC or PS2AC It also provides more room for wiring than is available when using the supplied flat knockout plate There is a 2 inch TSC cut out on the plastic box to allow it to be used with the PSAC or PS2AC disconnect enclosure FX DCA DC CONDUIT ADAPTER The FX DCA allows the connection of 2 inch TSC conduit to the FX It fits on the opposite end of the FX from the AC wiring compartment The location of the 2 inch conduit opening matches the 2 inch knockouts provided in the PSDC or PS2DC enclosure When installing an FX with a PSDC or PS2DC disconnect enclosure both the FX DCA and FX DCC are required FX DCC DC COMPARTMENT COVER The FX
66. e AUX OUTPUT FUNCTION screen described on the previous page There are voltage and time period settings for GenAlert LoadShed VentFan and Diversion The following displays allow the adjustment of the particular AUX OUTPUT FUNCTION that was selected on the previous screen in the AUX menu section ADV FX AUX POO genalert 11 0 vdc on setpoint DOWN INC DEC PORT ADV FX AUX POO genalert 4 min on delay DOWN INC DEC PORT ADV FX AUX POO genalert 14 0 vdc off setpoint DOWN INC DEC PORT ADV FX AUX genalert off delay DOWN I ADV FX AUX POO loadshed 11 0 vda off setpoint DOWN INC DEC PORT ADV FX AUX POO ventfan 13 0 vde on setpoint DOWN INC DEC PORT ADV FX AUX POO ventfan off 5 min period DOWN INC DEC PORT ADV FX AUX POO diversion 14 6 vdc on setpoint DOWN INC DEC PORT ADV FX AUX POO diversion 30 sec off delay DOWN INC DEC PORT ADV FX AUX aux output setup completed TOP ADV MAIN Installation amp Programming Manual Page 50 The GENALERT ON SET POINT is the battery voltage at which the AUX output is energized when the AUX OUTPUT FUNCTION has been set to GENALERT This setting has a range between 10 0 vdc and 14 0 vdc in 0 1 vdc increments The GENALERT ON DELAY is the amount of time that the battery voltage must rem
67. e current draw of the FX to a minimum The way to rank the slaves is called power save level slave adjust only The number you program for each FX is the slave rank and the master will know which FX to turn on next POWER SAVE LEVEL MASTER ADJ UST ONLY This setting is a manual selection of what slave FX s you want on From the factory the setting is zero and no slaves will be on until the master needs help If you set this number to 1 the We ranking slave power save level slave adjust only 1 will be on regardless of the loads on the system If you set this number to 2 the 1 and 2 ranking slave power save level slave adjust only 2 will be on think you get the picture Up to rank 7 can be selected Remember that if you set this number your idle power can t go as low as possible Power save level master adjust only is useful when you re working out in the shop and you want everyone helping out before the master asks for them It is also used to test the Power Save Level Slave Adjust Only programming when first setting up the system to make sure that all the FX s are stacked properly Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 24 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 AUTOMATIC GENERATOR START INSTRUCTIONS Te The Aux output of the FX can be programmed to start a 2 wir
68. e gas or diesel generator automatically when the batteries need charging If you wish to use this option follow the instructions below Starting from the main menu press the lt ADV gt button to get into the advanced menu see page 43 for the password From the Advanced menu press the lt PG2 gt button then the lt PG3 gt button then the lt AUX gt button to get into the auxiliary output options The first menu that comes up is the aux output control which tells the FX to keep the aux output off on or automatically do what the auxiliary output function is In this case we want to keep the default setting on AUTO Press the lt DOWN gt button to get into the aux output function menu This is the menu where we tell the auxiliary output what function we want it to be In this case we want it to start a generator The default setting is CoolFan so press the lt DEC gt button 3 times so the display reads GenAlert Now that the function is set to start a 2 wire start generator the start and stop parameters need to be set Press the lt DOWN gt button to get into the genalert on setpoint menu This menu adjusts the battery voltage set point to where you want the generator to start at The default setting is 11 22 or 44 volts depending on your FX which you can adjust Press the lt INC gt or lt DEC gt buttons to change this setting Press the lt DOWN gt button to get into the genalert on delay menu This m
69. e repair or replacement of the product at OutBack Power Systems discretion OutBack Power Systems does not warrant or guarantee the workmanship performed by any person or firm installing its products THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE OR JURISDICTION TO JURISDICTION OUTBACK POWER SYSTEMS RESPONSIBILITY FOR MALFUNCTIONS AND DEFECTS IN HARDWARE IS LIMITED TO REPAIR AND REPLACEMENT AS SET FORTH IN THIS LIMITED WARRANTY STATEMENT ALL EXPRESS AND IMPLIED WARRANTIES FOR THE PRODUCT INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF AND CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE LIMITED WARRANTY PERIOD SET FORTH ABOVE AND NO WARRANTIES WHETHER EXPRESS OR IMPLIED WILL APPLY AFTER SUCH PERIOD SOME STATES OR JURISDICTIONS DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU OUTBACK POWER SYSTEMS DOES NOT ACCEPT LIABILITY BEYOND THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY STATEMENT OR LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION ANY LIABILITY FOR PRODUCTS NOT BEING AVAILABLE FOR USE SOME STATES OR JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION OR LIMITATION MAY NOT APPLY TO YOU During the two year period beginning on the invoice date O
70. e user to the top of the ADV FX STACK menu section Selecting ADV returns you to the advanced screen to allow selection of another product connected to the MATE Selecting MAIN returns the display to the MAIN screen FX amp FX Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 51 MATE ADVANCED SELL The SELL section is used to set the functions that control the process of selling power back to the utility grid This menu is only operational for Grid Tie FX s and is not operational with Export FX s at this time These functions include setting the voltage at which the FX sells back to the utility grid setting the window in which the Grid Tie function operates and to enable or disable the Grid Tie function The default values enable the Grid Tie FX to sell back to the utility grid after the FX has completed a charge cycle To disable this charge cycle press the lt AC IN gt hot button four times press lt BULK gt press lt STOP gt and then press lt OK gt The FX waits 5 minutes after it has accepted the utility grid as an AC source and must be above the sell RE volts found in this menu to start selling ADV FX PAGE1 Once the password has been correctly entered the ADV CHOOSE CATEGORY screen is choose category displayed Selecting lt PG2 gt shows a s
71. e user to the top of the STATUS FX BATT menu section Selecting STATUS returns to the STATUS screen FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 37 MATE STATUS ERRORS po gt gt gt al The ERROR section allows the user to check the cause of an error condition when the FX shuts down When an error has occurred the red error LED indicator in the FX s wiring compartment will be illuminated not to be confused with a blinking LED that indicates a WARNING If an error occurs the FX will cease operation and the MATE will display an error screen Pressing lt VIEW ERROR gt from this screen brings the user to a list of error causes that will be available by pressing the DOWN button The particular error that the FX is experiencing will be displayed on the MATE by the presence of the word YES next to the appropriate cause An error can be cleared by pressing the lt INV gt button on the MATE and then turning the FX lt OFF gt and then back again to lt ON gt Once the error has been cleared and the inverter reset the display will change back to NO as shown on the screens below The inverter automatically resets from an over temperature and low battery conditions NA IN 4 SUM STATUS S 6 54 42P ETUP ADV STATUS choose produ FX MX cle STATU
72. e within range of your voice to come to your aid 2 Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes 3 Wear complete eye protection Avoid touching eyes while working near batteries Wash your hands with soap and water when done 4 If battery acid contacts skin or clothing wash immediately with soap and water If acid enters eye immediately flood eye with running cool water for at least 15 minutes and get medical attention immediately 5 Baking soda neutralizes lead acid battery electrolyte Keep a supply on hand in the area of the batteries 6 NEVER smoke or allow a spark or flame in vicinity of a battery or generator 7 Be extra cautious to reduce the risk of dropping a metal tool onto batteries It could short circuit the batteries or other electrical parts that may result in fire or explosion 8 Remove personal metal items such as rings bracelets necklaces and watches when working with a battery A battery can produce a short circuit current high enough to weld a ring or the like to metal causing severe burns 9 If a remote or automatic generator start system is used disable the automatic starting circuit and or disconnect the generator from its starting battery while servicing it to prevent starting while servicing Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington W
73. econd screen of categories ADV INV CHGR PG2 ADV FX PAGE2 Selecting lt PG3 gt shows a third screen of categories choose category PG1 GRID GEN PG3 ADV FX PAGE3 Selecting lt PG4 gt shows a fourth screen of categories choose category PG2 AUX STACK PG4 ADV FX PAGE4 Selecting lt SELL gt allows adjustment of the Grid tie and selling set points and operation choose category PG3 SELL CAL MAIN ADV FX SELL P00 The SELL RE VOLTS RE Renewable Energy screen allows the user to set the voltage at re 12 8vdc which they would like to sell battery power back to the utility grid If the battery voltage is above DONN INC DEC PORT the voltage shown on this screen and the FX isn t charging then the FX will sell power back to the utility grid This setting has a range between 10 0 vdc and 15 0 vdc in 0 1vdc increments ADV FX SELL POO The GRID TIE WINDOW screen controls the voltage and frequency windows that the grid tie grid tie IEEE function operates in If the FX repeatedly disconnects from the utility grid this value may need to window be changed This function should not repeat should not be changed without consulting DOWN je Meee OutBack Power Systems first ADV FX SELL POO The GRID TIE AUTHORITY screen allows the user to turn on or off the selling function of the FX grid tie GridTie When
74. en When the FX is in the Float charging stage the float time remaining value appears and starts to count down The REFLOAT SET POINT is the battery voltage at which the battery charger will restart the float charging process and hold it there for the FLOAT TIME PERIOD This setting is compared with the BATTERY ACTUAL voltage This is the battery charger set point for the equalize stage of the battery charging process The voltage will be held at the EQUALIZE VOLTAGE SET POINT level for the equalize time period that is programmed in the ADVANCED menu section The equalization process must be manually triggered while an AC source is connected to the FX s AC input Equalize can be triggered by pressing the AC IN button four times pressing the EQ button then selecting START The EQUALIZE TIME REMAINING is the amount of time remaining for the equalize stage of the battery charging process Once the EQUALIZE TIME period has been met the charger turns off When the FX is in the Equalize charging stage the equalize time remaining value appears and starts to count down The BATTERY TEMP is a reference value used by the battery charger when an RTS is connected to the FX A displayed value of 255 means the sensor is not connected or has been damaged At normal room temperatures a value around 130 15 will be shown As the battery temperature increases the value displayed will get lower and vice versa Selecting TOP returns th
75. ent mode again until the battery voltage drops to the Refloat Setpoint This fifth stage REFLOAT will start another FLOAT charge There are additional screens for Equalize Setpoint and Equalize Time Period An equalize charge must be manually started and should be performed once every three months The time limits that it spends in the various stages are adjustable to provide control and maximize the performance of the battery charger and battery system Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 23 STACKING INSTRUCTIONS HOW TO FIND THE STACKING MENU ADV PASSWORD FX PG2 PG3 STACK Read the MATE portion of this manual for more info For 3 phase stacking a jumper must be set to the 3 ph position in the HUB See HUB manual for further information STACK PHASE Stack phase establishes which FX is the master and which FX s follow the master s commands Select the stack phase that suits your system whether it s a parallel 230 vac or 3 phase 230 400 vac system 1 2 PH MASTER 1 2 PH MASTER is used for stand alone FX units OR as the MASTER of a single phase system Set the stack phase of the FX you want as the master to 1 2 PH Master default and make sure it is in port 1 of the HUB The 1 2PH MASTER FX is always considered to be
76. enu adjusts the time you will allow the battery to be at the genalert on setpoint before starting the generator The default setting is 4 minutes at the genalert on setpoint and the generator will start Press the lt INC gt or lt DEC gt buttons to change this setting Next you want to stop the generator at some point so you also need to set that value Press the lt DOWN gt button to get into the genalert off setpoint menu This menu adjusts the battery voltage set point to where you want to stop the generator The default setting is 14 28 or 56 volts depending on your FX which you can adjust Press the lt INC gt or lt DEC gt buttons to change this setting Press the lt DOWN gt button to get into the genalert off delay menu This menu adjusts the time you will allow the battery to be at the genalert off setpoint before stopping the generator The default setting is 9 minutes at the genalert off setpoint and the generator will stop Press the lt INC gt or lt DEC gt buttons to change this setting Even though you have set the off function for the generator there are two other ways that the auxiliary output can stop the generator If the charger settings of the FX reach float or silent mode that overrides the genalert off setpoint because the FX figures that the batteries are charged The generator will turn off based on whatever comes first genalert off float or silent If you want to stop the
77. eries Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 21 START UP amp OPERATION Once the FX system installation is completed it is time to power the system Leave the breakers on the AC side in the OFF position until the FX s are powered and programmed Power the FX s by switching the DC disconnect breakers to the ON position The LED s Light Emitting Diodes in the AC compartment of each FX will begin to light For each FX one BATTERY LED will be lit This BATTERY LED should be either the green FULL LED or yellow OK LED If the red LOW LED is lit check the battery voltage and the battery to FX cabling for reasons why the FX thinks the batteries are low The other set of STATUS LED s will begin to light The red ERROR LED may blink a few times but this is just a symptom of powering the FX About 5 seconds to 10 seconds after power is applied the green INVERTER LED will be lit with the AC IN and ERROR LED s not lit At this point the FX is producing an AC output voltage If the user were to connect AC loads to the FX the FX would use battery power to power the loads Before doing this the programming of the FX should be performed using the MATE If applicable this programming should include choosing the AC input type of grid or generator generator is the default see page 42 f
78. g If multiple FX s or an FX and an MX 60 charge controller are both in the system an OutBack HUB communication manager is be required for stacking of the FX s and for efficient system performance The HUB acts similar to a computer hub to combine the communication signals of the devices together into a networked system OutBack offers two different HUB products at this time The HUB 4 accepts up to four OutBack products and one MATE The HUB 10 connects up to ten OutBack products and one MATE NOTE Although the HUB has 2 ports for MATE s only the je port is operational Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 13 BATTERY FX CABLING a jj jaOJ EZO J JFHvv Ts DC BATTERY TERMINALS The DC terminals are made from solid brass with a stainless steel threaded stud The threads are M8 x 1 25 The black terminal is negative and the red terminal is positive DO NOT PUT ANY WASHERS BETWEEN THE TERMINAL MOUNTING SURFACE AND THE ACTUAL BATTERY CABLE LUG Place the flat washer lock washer and nut on top of the battery terminal lug TORQUE TO 60 INCH POUNDS 5 FOOT POUNDS OR 6 8 NM MAXIMUM UL listed DC rated circuit breakers are available from OutBack Power Systems with amperages of 100 175 and 250 amps DC All of the OutBack DC breakers come wi
79. g the Absorb Time Limit is tougher and requires some experimenting and calculations We will be assuming that the generator or the utility grid will be the only device charging the batteries A general rule for knowing when the batteries are fully charged and the absorption cycle can be stopped is the formula C 40 C is your battery bank capacity which you divide by 40 So take the total amp hour capacity of the batteries and divide it by 40 The resulting number is the DC current at which the batteries are fully charged Write this number down Next divide the DC Current by the number of FX s that will be charging the batteries This is your new DC Current Next do a calculation to find the AC Current needed to produce this DC Current by following this formula DC Current x Absorb Voltage AC Current ___1_Y_ WY Y Round this number down to the nearest integer AC Input Voltage Next through the MATE follow the path MAIN ADV any button PASSWORD 141 FX CHGR DOWN DOWN The screen should show Absorb Time Limit Set this value arbitrarily high say 4 hours To set the correct time in the Absorb Time Limit the user must perform the following experiment on the system First the user should discharge the batteries to the recommended depth of discharge and then connect the AC input to all FX s charging the batteries and let the FX s charge the ba
80. generator based on float or silent extend the genalert off delay beyond what is capable of the charger to achieve The following schematic shows how to hook up a relay that interfaces with the 2 wire start generator 3 wire start generators require an adapter like the Atkinson GSCM available at www atkinsonelectronics com Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming M anual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 25 MATE SYSTEM CONTROLLER AND DISPLAY System Controller and Display The OutBack MATE system controller and display allows you to program control and monitor the operation of one or more FX s as well as the MX60 MPPT charge controller When connecting a MATE to more than one product is reguired a HUB 4 or HUB 10 communication manager must be included in the system The MATE can be located up to 1000 feet 305 meters from the FX system using standard 8 conductor CAT5 type communication cabling This wiring is considered to be a low voltage limited energy circuit The MATE can be used to program the FX and then removed All of the settings in the FX are stored in non volatile memory inside of the FX itself the battery can be removed from the FX and the settings will not be lost The MATE also allows for monitoring and control of the FX system s operation Some of the more a
81. ing hook up see wiring instructions in this manual This product is intended to be installed as part of a permanently grounded electrical system 4 AC overcurrent protection for all connections must be provided by others as part of the installation 5 DC battery circuit overcurrent protection must be provided by others as part of the installation OutBack offers 100 175 and 250 amp DC breaker part number OBDC XXX which can be used with the FX OutBack also offers a stud mounted fuse which can be connected directly to the positive DC terminal of the FX it is available in 100 175 and 250 amp sizes part number SMF XXX The Stud mounted fuses require a 10mm hole in the battery terminal lug US lugs are typically 3 8 diameter Light filing may be required to insure proper fit of the nut shoulder into the lug hole 6 The equipment ground on the inverter is marked with this symbol 7 This inverter has a single phase output It is marked with this symbol 2 VW 8 This inverter puts out a sine wave waveform It is marked with this symbol 9 CAUTION To reduce the risk of fire connect only to a circuit provided with 30 amp maximum branch circuit overcurrent protection Installation amp Programming M anual FX amp VFX E Series Inverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 6 Rev 7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 IMPORTANT SAFETY INSTRUCTIONS
82. installations The system with four FX s is shown mounted to the OutBack PSMP Power System Mounting Plate The PSMP comes with six 1x20mm thread forming screws for attaching FX s and breaker boxes The use of an external toothed star washer provided is required on one screw on each piece of equipment in order to bite through the powder coating and ensure grounding of all metal components The system with two FX s is shown mounted to the smaller OutBack PS2MP the 2 in PS2MP refers to the maximum number of FX s that will fit power system mounting plate The mounting plate will typically need to be bolted to the studs in a wall using at least four 1 4 or 5 16 lag bolts 2 long In addition to the mounting plate these installations are also shown with an OutBack PSDC or PS2DC DC breaker box PSAC or PS2AC AC breaker box FX DCA DC Conduit Adapter FX DCC DC Compartment Cover and the FX ACA AC Compartment Adapter When two or more FX s are installed in close proximity such as in this installation it may be useful to install one or more 12VDC fans inside the PSDC that will pressurize the PSDC enclosure forcing air up through the DC Manifold and down over the external fins This will improve the battery charging performance by reducing the possibility of the FX s limiting the output due to reaching their maximum allowed temperatures The AUX outputs of the FX s can be used to control and power the cooling fans These a
83. is a generator it may be possible to adjust the frequency of the generator The ACIN VOLTAGE gt MAX screen indicates that the AC source s voltage exceeded the maximum AC voltage the FX allows 270 vac default This value can be adjusted in the ADVANCED menu in the GRID or GEN sections depending on your input type The FX disconnects to protect the loads from high voltage If you expect significant voltage drop due to long cable runs it may be safe to raise the limit The ACIN VOLTAGE lt MIN screen indicates that the AC source s voltage is below the minimum AC voltage the FX allows 208 vac default This value can be adjusted in the ADVANCED menu in the GRID or GEN sections depending on your input type The FX disconnects to protect the loads from low voltage If your AC source operates near this voltage limit it could affect the charging function the FX backs off the charger if the AC voltage reaches the lower limit and adjusting the limit lower may be in order Selecting TOP returns the user to the top of the STATUS FX DISCON menu section Selecting STATUS returns to the STATUS screen to allow selection of another product FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE STATUS SELL The SELL section of the STATUS menu has only one screen This screen gives a number that refers
84. is overloaded See the next page to adjust the set points for this function Selecting COOLFAN default enables the AUX output to function as a thermostatically operated ventilation system controller When the FX approaches an over temperature condition the AUX output will be energized This can be used to power a small 12 vdc brushless muffin type fan the Turbo Kit or can be used to control a larger cooling fan via a 12 vdc coil relay Selecting VENTFAN enables the AUX output to function as an automatic battery ventilation system controller The AUX output can provide 0 7 amps of power for connection to a 12 vdc brushless muffin type fan The fan will be automatically turned on when the voltage exceeds the VENTFAN ON voltage set point The fan can be set to operate intermittently by adjusting the VENTFAN OFF TIME PERIOD See the next page to adjust the set points for this function Selecting FAULT enables the AUX output to function as an alarm output When the FX enters any of the error conditions the AUX output is energized This can be used to send an alarm signal via radio pager or telephone dialer It also can be used to log error conditions by using it to trigger an event recording device Selecting GENALERT enables the AUX output to function as a simple voltage controlled generator start signal GenAlert can be used to alert the system user to start the generator due to the battery voltage being low Only connection to
85. itional AC pulses The larger this search pulse spacing number is the lower the power consumption but the more noticeable the delay becomes when an AC load is first turned on This setting has a range between 4 cycles and 120 cycles 2 seconds in 1 cycle increments The LOW BATTERY CUT OUT setting determines when the inverter will turn off to prevent over discharge of the battery system If an AC source is available and the AC INPUT was set to DROP the FX will transfer all of the AC loads on the inverter to the AC source A fixed delay of 5 minutes is included to reduce nuisance inverter shutdowns This setting has a range between 9 0 vdc and 12 0 vdc in 0 1 vdc increments The LOW BATTERY CUT IN setting determines when the inverter will turn back on after it had shut off due to a low battery situation A fixed delay of 10 minutes is provided to reduce the possibility of the system cycling on and off This setting has a range between 10 0 vdc and 14 0 vdc in 0 1 vdc increments The ADJ UST OUTPUT VOLTAGE setting allows the user to change the output voltage to a lower or higher voltage This may be necessary if some loads are far away from the FX or if some loads are sensitive to higher voltages This setting has a range between 210 vac and 240 vac in 2 vac increments The RESET FX TO FACTORY DEFAULTS changes all of the settings in the FX back to the factory default set points THIS WILL CAUSE ALL OF THE PREVIOUS PROGRAMMING TO BE LOST Sele
86. lecting MAIN will return the user to the MAIN screen Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 44 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE ADVANCED INVERTER The INVERTER category of the advanced menu section allows adjustment of the inverter s operation to match the AC load and battery requirements Specifically this section allows adjustment of the Search function the low battery cut out function the FX s AC output voltage and allows the user to reset the FX to its factory defaults ADV choose product FX MX ATE MAIN ADV FX PAGE1 choose category ADV INV CHGR PG2 ADV FX INVERTER P00 search 6 sensitivity DOWN INC DEC ADV FX INVERTER P00 search 8 cycles pulse length DOWN INC DEC ADV FX INVERTER P00 search 60 cycles pulse spacing DOWN INC DEC ADV FX INVERTER P00 low battery 10 5 vdc cut out set point DOWN INC DEC ADV FX INVERTER P00 low battery 12 5 vdc cut in set point DOWN INC DEC ADV FX INVERTER P00 adjust 230 vac output voltage DOWN INC DEC ADV FX INVERTER reset FX to factory defaults DOWN MORE ADV FX INVER
87. lights with magnetic ballasts MAIN The MAIN screen is where the menu system starts The four words in the bottom line of the 6 54 42P display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two SUM STATUS SETUP ADV buttons simultaneously from anywhere in the menu will return you to this screen SETUP Allows selection of the product type choose product lt FX gt FX inverter charger system MATE MATE system display and user interface FX MATE SETUP FX The categories are then displayed for the settings which can be adjusted in the setup menu choose category lt SRCH gt Allows adjustment of the settings for the Search mode INPUT Allows selection of the AC INPUT and current limit adjustment SRCH INPUT MATN MAIN Returns the display to the MAIN screen The SEARCH SENSITIVITY setting determines how much AC load watts is required to make the FX switch from the search mode to the normal inverter on mode Increasing the number INC decreases the sensitivity more watts must be turned on to bring the FX out of search while decreasing the number DEC increases the sensitivity less watts must be turned on to bring the FX out of search Adjusting this setting to zero will effectively disable the search mode operation SETUP FX SEARCH
88. ly give you a description of what meter is being displayed or what parameter is currently set in the MATE The bottom line on the MATE is almost exclusively used for labels to the four soft keys below Each button below the bottom line of the MATE s display corresponds to the word directly above it This manual will denote soft key button presses as lt BUTTON gt where BUTTON corresponds with the label displayed on the screen directly above the soft key NOTE Pressing the left two buttons simultaneously from anywhere in the menu will return you to the MAIN menu screen Installation amp Programming M anual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 28 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE SYSTEM CONTROLLER AND DISPLAY E SOFT Keys The four buttons under the LCD are referred to as the soft keys Their operation is dependent on what their label says The label is the word on the bottom line of the LCD directly above the button Soft keys used to navigate the menus are commonly labeled lt UP gt lt DOWN gt lt NEXT gt lt BACK gt or lt TOP gt Soft keys that change settings are labeled either with the change they will make such as lt OFF gt lt AUTO gt and lt ON gt or if there are more than a couple values that the setting can be changed to lt INC gt and lt DEC gt are used to mean incre
89. mming Selecting MX will allow access to the advanced sections of any MX 60 s connected to the system through a HUB Selecting MATE will allow access to the MATE s advanced screens Selecting MAIN returns the user to the MAIN menu ADV choose product FX MX ATE MAIN ADV FX PAGE1 h k re There are eight categories of settings in the FX ADV INV CHGR PG2 INV Allows adjustment of the INVERTER settings and operation CHGR Allows adjustment of the CHARGER settings and operation FR GRID Allows adjustment of the AC input settings and operation if the FX s input is set to GRID i GEN Allows adjustment of the AC input settings and operation if the FX s input is set to GEN PGl GRID GEN PG3 AUX Allows adjustment of the AUX OUTPUT settings and operation STACK Allows adjustment of the master slave settings for multi FX systems ADV FX PAGE3 SELL Allows adjustment of the Grid Tie settings and operation choose category k CAL Allows adjustment of the voltage calibration measurements to improve operation PG2 AUX STACK PG4 ADV FX PAGE3 Selecting ADV will send the user back one screen to the choose product screen in the advanced choose category menu PG2 will advance the user to page 2 of the advanced menu PG3 will advance the user to page 3 of the advanced menu PG4 will advance the user to page 4 of the advanced menu PG3 SELL CAL MAIN Se
90. mode AC current flows directly from the AC source generator or grid through the bypass breaker and out to the loads In addition to the AC bypass switch Outback has separate AC input breakers These also need to be turned off After the FX has been powered down through the DC breaker the FX can then be removed for servicing or replacement without loss of AC power to the AC loads of the system The AC terminal block includes two terminals labeled CHASSIS GROUND older FX s have on of these terminals labeled Filter Ground even though it was never actually filtered These terminals are connected to each other within the FX Therefore it is necessary to connect only one of these terminals to ground It should be noted that the grounding lug near the battery terminals may also be connected to ground Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 12 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 INDICATORS CONTROL WIRING The AC wiring compartment also encloses the green terminal block used for the low voltage control wiring This six position terminal block can be unplugged to make wiring easier and to simplify the removal and reinstallation of an inverter Two sets of multi colored LED indicators are provided to display the operation of the system One set of three LED s is provided to indicate the
91. mp Programming M anual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 35 MATE STATUS METERS The METER section lets the user view the AC voltage and AC current meters as well as the software revision of the FX s microprocessor The user can view the input and output AC voltages as well as the input inverter charger and sell currents This can be used to verify that the FX is sensing voltages and currents and also helps discern what the FX is doing like charging or inverting The software revision is helpful when troubleshooting Some functions of certain software revisions are incompatible with older MATEs STATUS FX PAGE1 choose category MODES METER BATT PG2 Invert POO inv 0 0kw zer 0 0kw chg 0 0kw buy 0 0kw DOWN STATUS PORT STATUS FX METER P00 output 230 vac voltage DOWN UP TOP PORT STATUS FX METER P00 input 230 vac voltage DOWN UP TOP PORT STATUS FX METER P00 inverter 0 0 aac current DOWN UP TOP PORT STATUS FX METER P00 charger 0 0 aac Current DOWN UP TOP PORT STATUS FX METER P00 input 0 0 aac current DOWN UP TOP PORT STATUS FX METER P00 sell 0 0 aac current DOWN UP TOP PORT STATUS FX METER P00 FX firmware 58 revision DOWN UP TOP PORT STATUS FX ME
92. mp 10 OutBack MX60 MPPT charge controllers can use any of the remaining ports provided no FX s are used Future OutBack products will also be compatible with the HUB When using the HUB the MATE must be plugged into the 1 MATE port of the HUB The MATE must be the last device plugged into the HUB for proper operation The HUB manages both the inter FX communications and the MATE FX communication When a HUB is used the RTS Remote Temperature Sensor must be plugged into the Master FX which must be plugged into port 1 of the HUB If this is the case only one RTS is required for all devices plugged into the HUB When two or more FX s are stacked in a parallel configuration the system automatically turns off any excess slave FX s to save power and maximize conversion efficiency This power save system is fully automatic and works with or without the MATE connected to the system On 3 phase systems there is a limit of one FX per phase totaling three FX s In the future the HUB will be capable of multiple FX s per leg of a 3 phase system To convert the HUB into 3 phase mode please read the HUB instruction manual One MATE system controller and display can be connected to the HUB Although there are two Mate ports on the HUB only the 1 Mate port is currently operational The MATE can be located up to 1000 feet 300 meters from the HUB system location Cabling from the HUB to the MATE is completed using standard CAT5 type ethernet comm
93. ms PS system is recommended This FX system will require one AC IOB 60Q bypass kit The AC IOB 60Q bypass kit includes two QOU 60 amp breakers for the bypass and four 30 amp CBI breakers for the AC outputs The quad FX system will require four additional CBI 30 amp breakers for the AC input Additional breakers can be purchased and installed in the PSAC if necessary The AC wiring from the AC source and to the AC loads must handle 120AAC or more The AC wiring connected to the QUO 60A dual bypass breakers must handle 60 amps AC or more All other AC wiring must handle a capacity of 30 amps AC or more This type of FX system can continuously power 8 12KW of loads depending on which model is used Connecting more power than the continuous rating of the FX may cause breakers to trip or the FX to shut off its AC output A HUB and a MATE must be connected to stack these FX s in parallel A MATE through the HUB if one is needed must be connected to adjust any parameters or to display any meters Once the FX has been programmed using the MATE the MATE can be disconnected The programming will be saved within the FX s non volatile memory even if the FX is completely shut down The diagram below represents parallel stacking of four FX s
94. nd will be lower than the actual battery voltage when the battery is cold This is the battery charger set point for the absorb stage of the battery charging process The voltage will be held at the ABSORB VOLTAGE SET POINT level for the ABSORB TIME LIMIT period that is set in the ADVANCED menu section This value can only be changed in the ADVANCED meru The ABSORB TIME REMAINING is the period of time remaining for the absorb cycle When the FX is performing an absorb charge this time value will start counting down once the absorb voltage has been reached When this value reaches 0 0 hrs the FX will go into SILENT charger turns off mode until the battery voltage drops to the FLOAT voltage This is the battery charger set point for the float stage of the battery charging process The voltage will be held at the FLOAT VOLTAGE SET POINT level for the float time period that is programmed in the ADVANCED menu section After leaving the absorb charging stage the charger first turns off and waits for the battery voltage to drop to this float voltage set point before the charger begins to float the battery The FLOAT TIME REMAINING is the amount of time remaining for the float stage of the battery charging process The battery charger does not continuously float the batteries It instead only floats for the FLOAT TIME LIMIT period set in the ADVANCED menu section Once the time period has been met the charger turns off called SILENT on the SUMMARY scre
95. nection of an optional external battery temperature sensor the RTS sold separately that allows for automatic adjustment of the battery charging process based on the temperature of the battery Battery manufacturers provide recommended charge voltages based on temperatures of 25C 77F With the RTS attached the FX adjusts the battery voltage 0 03 volts per degree Celsius for a 12 volt battery bank 0 06 volts per degree Celsius for a 24 volt battery bank or 0 12 volts per degree Celsius for a 48 volt battery bank When a HUB is used the RTS must be plugged into the Master FX which must be plugged into port 1 of the HUB If this is the case only one RTS is required for all devices plugged into the HUB The RTS should be stuck to the side of a battery below the electrolyte level so it can measure the temperature of the batteries The wire from the RTS can be folded and routed underneath the transparent gray plastic lexan cover of the AC wiring compartment to allow connection to the battery There is a small indentation in the aluminum casting to allow for the wire to pass without affecting the sealing of the covers When running additional wires under the smoked lexan cover it may be required to snip some lexan away to allow for wire routing The lexan will not crack when cutting or filing MATE HUB The 8 position Ethernet RJ 45 modular jack allows direct connection of a MATE system controller and display to the FX using standard CAT5 type cablin
96. nnected and the AC loads are drawing power AC Load P aS e ot a from the AC source that is passing through the FX The top line shows 0 0 kW indicating that Buying the charger is in SILENT mode and is not charging the batteries Approximately 1 0 kW loads Beri L n OV are being powered from the AC source assuming the system consists of one FX DC JAC gt gt gt 1 7kW BUYING CHARGING amp PASS THROUGH The FX is buying four 2 0kW more power AC Load x ar than it is delivering to the loads one 3 0 5kW This is an indication that the FX is using the Buying S8 excess power to charge the batteries The charger is charging at a rate of 1 7 kW of AC power Battery 13 4V going into the battery The AC loads are low and are being powered from the AC source DCE AC gt gt gt gt gt 2 5kW AC DROP The inverter is on and powering 2 5 kW of AC load from the batteries The AC AC Toad ee a source is available but DROP was selected in the AC INPUT CONTROL This will also be HA DE GEA Wi Aase displayed when an AC source is available but not in use such as during the initial time delay PALESI TEN period once an AC source has been connected DCEJAC gt gt gt gt 2 2kW SELLING The FX is selling power back to the utility grid at about 1 5kW It is also supplying AC Load x t about 0 5kW of AC loads The FX is taking about 2 2kW of power from the batteries This Selling excess battery power is coming from a different
97. ol provided by the OutBack MATE if the switch is set to OFF the MATE will not be able to turn ON the inverter Cycling this switch quickly from ON to OFF and then to ON again puts the inverter into Search mode Cycling the switch in this fashion again returns the inverter to the ON mode AUXILIARY OUTPUT AUX AUX The Auxiliary output system uses the AUX and AUX terminals and is able to be programmed through the MATE to do a variety of tasks The default use for these terminals is to drive one 12 volt fan for external cooling The power available at these terminals is 12 VDC at 0 7 amps 8 4 watts maximum These terminals should not be connected to any type of DC load which has a high inrush current requirement The FX includes internal electronic overcurrent protection for this 12 VDC output circuit which auto resets if it is short circuited No additional fuses are required Use the OutBack FX Turbo Kit or DC12 FAN for cooling For automatic or advanced generator start functions the Auxiliary Output can drive a 12V automotive relay for the 2 wire starting circuitry of a generator OutBack Power Systems does not support 3 wire start generators however a 3 wire to 2 wire conversion kit is available from a different source XCT XCT These terminals are not operational at this time BATTERY TEMP REMOTE TEMPERATURE SENSOR RTS The OutBack GFX has a 4 position phone RJ 11 modular jack located in the AC compartment for the con
98. olts for a 12 volt FX for 5 minutes The inverter will restart once the battery voltage exceeds the LOW BATTERY CUT IN VOLTAGE set point 12 5 volts for a 12 volt FX for 10 minutes PHASE LOSS ERROR is not operational at this time If a Yes accompanies this Error please disregard HIGH BATTERY VOLTAGE indicates that the battery voltage rose above the high battery voltage level 20 volts for a 12 volt FX for 10 seconds The inverter will restart once the battery voltage drops below the high battery voltage level 20 volts for a 12 volt FX for 1 second AC OUTPUT SHORTED indicates that the inverter immediately reached its maximum current and shut down This is usually caused by a short circuit condition hence the AC OUTPUT SHORTED label but can also be caused by attempting to operate a load which far exceeded the inverter output capability AC OUTPUT BACKFEED indicates that another AC source of power was connected to the AC output of the FX Usually this is an installation issue It often occurs when there is an X 240 transformer in the system and the FX s haven t been programmed for stacking Programming the FX s for the correct stacking may erase this error Selecting TOP returns the user to the top of the STATUS FX ERROR menu section Selecting STATUS returns to the first page of the STATUS screen FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington W
99. or more info stacking of multiple FX s see pages 23 amp 50 for more info adjusting the charging set points using the battery manufacturers specification see page 45 for more info setting the time and the date on the MATE see MATE manual and programming of the Auxiliary output for the function you wish it to perform see pages 48 amp 49 for more info The FX system is now ready to perform per your specification Switch the AC breakers ON with the bypass mechanism switched to Normal Provided that the AC source to the FX s is available the yellow AC IN LED in the AC compartment will begin to blink If the voltage of the utility grid is within 208 vac to 270 vac and the frequency is within 46 Hz to 54 Hz the FX will connect to the utility grid This process takes about 30 seconds and the AC IN LED will stop blinking and stay lit When the AC IN LED is lit the AC transfer switch within the FX is activated and the utility grid or generator power is applied to the loads At this time the FX will perform a complete charge on the batteries This charging process will Bulk raise the battery voltage until they reach the Absorb voltage The FX will maintain this Absorb voltage for the Absorb Time Period default of 1 hour After the Absorb stage the FX performs a Float charge It lets the battery voltage drop to the Float voltage and it then sustains this voltage for the Float Time Period
100. p from overloading the generator This setting has a range between 2 5 aac and 30 0 aac in 0 5 aac increments Selecting TOP returns the user to the top of the SETUP FX INPUT menu section Selecting SETUP returns you to the setup screen to allow selection of another product connected to the MATE Selecting MAIN returns the display to the MAIN screen FX amp VFX E Series Inverter C harger System Installation amp Programming Manual Rev 7 0 07 02 04 Page 43 MATE ADVANCED MENU The ADVANCED ADV menu section allows adjustment of all the settings involved with the operation of the FX Changes made to these settings are stored internally in non volatile memory inside of the FX the settings are not lost when the MATE is removed or battery power is disconnect Some settings appear both in the SETUP and in the ADV menus Changes made to these settings in one area will cause the same changes to occur in the other area The settings are provided in both menus to make it more convenient for the FX programmer by giving access to all of the settings in the advanced menu Access to the settings in the ADV menu is restricted through the use of a password This password is required to view and adjust the settings Once the password has been entered all advanced categories can be adjusted without having to re enter the password If the advanced menu is exited and re entered the password must be re entered however Use of the hot keys AC IN
101. ramming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 5 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for the OutBack FX Export or E series inverter charger system with the software which allows parallel and 3 phase stacking of multiple units for higher power and or higher voltage systems 1 All of the AC field wiring terminals are to be torqued to 30 inch pounds equivalent to 2 5 foot pounds or 3 4 Nm Wiring to these terminals must meet requirements of the local electric code The terminals will accept up to GAWG 13 3mm Use copper conductors only with insulation rated for 75 C See the AC WIRING CONNECTIONS section of this manual for more information 2 Torque the DC connections to 60 inch pounds equivalent to 5 foot pounds or 6 8 Nm Cables to these terminals must use a crimp on type ring terminal or compression type lug Cable must meet the requirements of the National Electrical Code Use of large gauge cables 2 0 AWG 68mm or 4 0 AWG 107mm or larger is advisable to reduce losses and ensure high performance of the FX Cables of too small a gauge can result in poor performance and even damage the FX Keep the cables together as much as possible and ensure that both cables pass through the same knockout and conduit fittings to allow the magnetic fields of the cables to cancel 3 For equipment ground
102. rify a fan failure The fan should run for about 15 seconds on start up AIRTEMP shows a numerical value that the FX understands as a temperature The value comes from a sensor inside the FX that measures the temperature of the air This warning is given for troubleshooting purposes FETTEMP shows a numerical value that the FX understands as a temperature The value comes from a sensor inside the FX that measures the temperature of the FET s Field Effect Transistors This warning is given for troubleshooting purposes CAPTEMP shows a numerical value that the FX understands as a temperature The value comes from a sensor inside the FX that measures the temperature of the ripple capacitors This warning is given for troubleshooting purposes Selecting TOP returns the user to the top of the STATUS FX WARN menu section Selecting STATUS returns to the STATUS screen to allow selection of another product FX amp VFX E Series Inverter C harger System Installation amp Programming Manual Page 39 Rev 7 0 07 02 04 MATE STATUS DISCONNECT The FX includes a section that displays the reason for last DISCONNECT from the AC source This is helpful if the FX rejects the AC source and the user wants an explanation and help on rectifying the problem The FX will disconnect from an AC source if the AC source falls out of the FX s frequency or voltage ranges If the AC source disconnects from the FX and none of the reasons for disconnect are
103. rogramming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 42 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE SETUP INPUT The other settings currently accessible to the system user in the SETUP menu involve the AC INPUT The system user can specify what type of AC INPUT is being used whether it is a generator GEN or the utility grid GRID Following this are two screens one for GEN and one for GRID that allow the user to adjust the maximum AC current that the FX will allow to enter before the FX gives a warning MAIN 6 54 42P SUM STATUS SETUP ADV n ETUP hoose product Q FX MATE n ETUP FX hoose category Q SRCH INPUT MAIN SETUP FX INPUT P00 ac transfer Gen control DOWN GRID GEN PORT SETUP FX INPUT P00 acl grid 24 0 aac limit DOWN INC DEC PORT SETUP FX INPUT P00 ac2 gen 24 0 aac limit DOWN INC DEC PORT n ETUP FX INPUT input setup completed TOP SETUP MAIN Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 The MAIN screen is where the menu system starts The four words in the bottom line of the display correspond to the four buttons located below the display The word in BOLD on the bottom line indic
104. s a range between 0 hours and 24 hours in 0 1 hour increments ADV FX CHARGER Selecting TOP returns the user to the top of the ADV FX CHARGER menu section Selecting ADV charger programming returns you to the advanced screen to allow selection of another product connected to the MATE completed Selecting MAIN returns the display to the MAIN screen TOP ADV MAIN Installation amp Programming Manual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 46 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE ADVANCED GRID The GRID category of the advanced menu section allows for adjustment of the AC input voltage window and time delays to match the characteristics of the AC source if that AC source is the utility grid This setting can be found in the SETUP FX INPUT menu All OutBack Power System FX s other than the Grid Tie FX s have a default of GEN generator as the AC source If the AC source is the utility grid return to the SETUP FX INPUT section page 42 and change the AC Transfer Control screen to GRID ADV choose product FX MATE ADV FX PAGEL1 choose category ADV INV CHGR PG2 ADV FX PAGE2 choose category PG1 GRID GEN PG3 ADV FX GRID POO ac input 00 5 min connect delay DOWN
105. s into Silent mode until the battery voltage drops to the Refloat Setpoint REFLOAT will start another FLOAT charge There are additional screens for Equalize Setpoint and Equalize Time Period An equalize charge must be manually started The time limits that it spends in the various stages are adjustable to provide control and maximize the performance of the battery charger and battery system ADV Once the password has been correctly entered the ADV CHOOSE PRODUCT is displayed choose product Selecting lt FX gt allows adjustment of the FX s advanced programming FX MATE ADV FX PAGE1 Selecting lt C HGR gt allows adjustment of the battery charger set points and operation choose category ADV INV CHGR PG2 ADV FX CHARGER P00 The CHARGER LIMIT is the maximum amount of AC current that will be used by the FX to power the charger 4 0 aac battery charger In most systems this setting will not need to be changed This setting has a range as limit i low as 0 0 aac and as high as 6 0 aac to 10 0 aac depending on the model in 0 5 aac increments DOWN INC DEC PORT ADV FX CHARGER P00 The ABSORB SET POINT is the voltage that the batteries will be charged to during the first stage of absorb 14 4 vde the charging process This stage of charging raises the battery voltage higher than the nominal battery setpoint voltage and allows the batteries to regain their charge The A
106. s you to the previous page of the MODES menu Pressing the CHANGE MODE button opens a screen that gives the options of turning the charger OFF or putting the charger into AUTO where it will follow the 5 stage charging algorithm Pressing PORT will access the next FX if a HUB is present The AUX CONTROL screen lets you see the status of the auxiliary output Pressing the UP button returns you to the previous page of the MODES menu Pressing the CHANGE MODE button opens a screen that gives the options of turning the Aux OFF turning the Aux ON or putting the Aux into AUTO mode In AUTO mode it will follow the Aux Output Function and its parameters that can be set in the Advanced ADV menu Pressing PORT will access the next FX if a HUB is present STATUS FX MODE P00 chr control AUTO CHANGE DOWN UP ODE PORT STATUS FX MODE P00 aux control AUTO CHANGE DOWN UP ODE PORT STATUS FX MODE P00 The EQ ENABLED screen lets you see if the FX is in an equalize charging cycle and can also start eq enabled No or stop a cycle Pressing the UP button returns you to the previous page of the MODES menu CHANGE Pressing the CHANGE MODE button opens a screen that gives the options of START or STOP to UP ODE PORT initiate or cancel an equalize charge Pressing PORT will access the next FX if a HUB is present Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation a
107. snnensensnnene 11 AC WIRING CONNECTIONS wisiscsscsscsissnssssasonssesteduvssonsessessiesunasensensbssteauesssusenseasssduodsonss ao oba banko obhoda ka bajne kona 12 INDICATORS CONTROL WIRING vis ccsscosssconsesoscesconsseissssoseoseseonessoscessoasseosessosconsososvonessoscoseoansednessosconsossoassnonessdecoseeassnsnessdssonsonsssos 13 BATTERY FX CABLING sicscecsscssecesscosecessesssesseosoeesteasvansscoseseadeoessendeees eosvaesscosoeesteosasesscodoeeshecagesansseosossstensooessensoeesteastesssessoessteoseenod 14 FX ACCESSORIES aiaiai niei E NNT E EEE S AS S EEA ES A 15 HUB COMMUNICATION MANAGER svesesvessesessessesesvessesensessesenseneenenseneenensenseneneeneeneneenenneneenennensnneneenennenensennsnnenennenneneensnneneunenneneer 16 TURBOKIT INFORMATION i oscessccessessecoscossscosessoscostoapssosescoseossscosessoscescoanssosensbecoseoasscosessoscoseeanssesennensdecoseoasscosessosceseeasssonessoesoseouesess 17 FX SYSTEM CONFIGURATION virossa ias TN ENa N ENORET EE EETA NEE ANRE 18 START UP amp OPERA TION oari nnie EAEN RENE Anke ene ENEE EA kk 22 BATTERY CHARGING INSTRUCTIONS sessersvsenversvneneenenseneenenneneenennenenneneenennenennennenennensenennensenennennnennennenennennenennensenennensenennenneneer 23 STACKING INSTRUCTIONS a a nate ATOE ata E EATE nn AO O 24 AUTOMATIC GENERATOR START INSTRUCTIONS eesserevseveereveenensenesnensenevnensenesnensenesnansenennanssnesnennenennenennanasnennennanasvennenasveseee 25 MATE SYSTEM CONTROLLER AND DISP
108. ssed by the system user The SEARCH mode is an automatic system which reduces the power consumption of the FX during periods of no power demand It is primarily used for off grid applications where the power is being generated by solar panels or other renewable energy sources and the system user is concerned about conserving every possible watt of power Properly setup and operated SEARCH mode can save considerable amounts of power compared to keeping an inverter in the ON mode 24 hours a day The FX includes a load detection method that is called search mode in which the inverter produces a pulsed AC output to detect the magnitude of the AC load which is connected to the inverter AC output Once a large enough load has been turned on the inverter resumes normal operation providing continuous AC power If the AC load is reduced to a level below the SEARCH SENSITIVITY setting then the inverter turns off and the pulsed AC output search mode is resumed The power saved by using the SEARCH pulsing method comes both from the reduced consumption of the inverter itself and from the elimination of the power consumed by phantom AC loads appliances which consume power even though they are not operating The SEARCH SENSITIVITY setting can be adjusted to ignore small AC loads such as a VCR display etc Use of the search mode requires some tuning of the settings for the particular loads connected and may not work well with some loads such as fluorescent
109. stem This is not the same as the software version in the MATE Selecting TOP returns the user to the top of the STATUS FX METER menu section Selecting STATUS returns to the STATUS screen FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 MATE STATUS BATTERY e a The BATTERY menu section allows the user to check the status of the battery voltage and the battery charging process Both the actual battery voltage and the temperature compensated battery voltage are provided The battery charging process set points are displayed along with the associated timer for the charging process No adjustments are allowed from this section To change the battery charger s operation go the ADVANCED programming section The values displayed are not defaults STATUS FX PAGE1 choose category MODES METER BATT PG2 STATUS FX BATT P00 battery 12 2 vdc actual DOWN STATUS PORT STATUS FX BATT P00 battery 12 2 vdc temp compensated DOWN UP TOP PORT STATUS FX BATT P00 absorb 14 4 vdc set point DOWN UP TOP PORT STATUS FX BATT P00 absorb 01 0 hrs time remaining DOWN UP TOP PORT STATUS FX BATT P00 float 13 6 vdc set point DOWN UP TOP PORT STATUS FX BATT P00 float 00 0 hrs time remaining DOWN UP TOP PORT
110. tage If the FX is not connected to the AC source the two voltages can differ significantly The INVERTER CURRENT meter indicates the amount of current being supplied to the AC loads connected to the FX s AC output terminals when the inverter is ON and no AC source is connected Each aac amp AC equals approximately 230 watts of load When the FX system is connected to an AC source this meter will read 0 The CHARGER CURRENT meter indicates the amount of AC current being used by the battery charger of the FX Each aac amp AC equals approximately 230 watts of charge This meter will read zero when the FX is not connected to an AC source The INPUT CURRENT meter indicates the total amount of current flowing into the AC input of the FX Some of this power may be used by the battery charger with the remainder flowing through the AC transfer switch to the AC loads Passing Thru To estimate the amount of current being used by the AC loads subtract the CHARGER INPUT current value from the INPUT CURRENT value The SELL CURRENT meter indicates the amount of AC current that the FX is pushing back into the utility grid This screen is only operational on Grid Tie FX models Multiply this number by the INPUT VOLTAGE to get the power being sold back to the utility grid This menu displays the FX FIRMWARE REVISION number for the software loaded into the FX s microcomputer This may be required when troubleshooting or expanding your sy
111. th threaded studs out the back for connection to ring type terminal lugs ALWAYS INSTALL BREAKERS OR FUSES WITHIN THE POSITIVE BATTERY CABLE OutBack also offers stud mounted fuses SMF for non NEC code installations in 100 175 and 250 amp sizes The minimum recommended cable size varies with the DC voltage FX2012ET installations must use 4 0 AWG 107mm cable minimum VFX3024E VFX3048E and FX2024ET installations can use 2 0 AWG 68mm cable as long as the distances are short less than 10 feet 3 meters per cable FX2348ET installations can use 2 AWG 34mm cable as long as the distances are short less than 10 feet 3 meters per cable If longer distances are required increase the cable size to the next size as a minimum Keep the cables together as much as possible for their entire length Tying or taping the cables together is advisable EQUIPMENT GROUND TERMINALS A set screw type box lug is provided near the DC terminals to allow the connection of an equipment grounding conductor for the metallic chassis of the FX It is located behind the battery negative terminal on the top of the inverter casting A green ground symbol marks the location When mounting a GFX to an OutBack mounting plate PS2MP use a star washer under a mounting screw to provide a good connection to the mounting plate Connection to the ground terminal is not required BATTERY TERMINAL COVERS The Battery Terminal Covers simply snap on They are a little brittl
112. that the AC source s voltage is below the lower limit default is 208 VAC of its voltage window If an AC source was just applied to the FX the FX will not connect to the AC source until the voltage rises above the lower limit AC INPUT CURRENT EXCEEDS MAX indicates that the AC loads are drawing more current than the rating of the FX allows Exceeding this current limit for an extended period of time could cause the FX to fail Reduce the loads on the FX s AC output to prevent damage and make sure a 30A max breaker is used on the AC input line TEMPERATURE SENSOR FAULT indicates that one of the temperature sensors internally located in the FX is not working correctly The FX needs to be checked by a qualified repair technician The AIRTEMP FETTEMP and CAPTEMP warnings listed below can help with troubleshooting INTERNAL COMMUNICATION ERROR DETECTED indicates that a communication problem has occurred between the MATE and the FX This warning may occur if the communication lines between the FX and the MATE have been severed If this is the case turn the FX off and then on through the DC disconnect If this does not solve the problem call OutBack for assistance INTERNAL FAN FAILURE DETECTED warns that the fan mounted above the transformer inside the FX has stopped working or is not functioning properly This will eventually cause an INVERTER OVERTEMP error if the cause of the fan failure is not fixed Restart the FX and listen for the fan to ve
113. the L1 phase where the hot AC lines are colored black CLASSIC SLAVE Not recommended for EXPORT FX s OB SLAVE L1 Set the stack phase of the FX you want as the slave to OB Slave L1 and make sure it is in port 2 or higher of the HUB OB Slave L1 is used for FX s that run in parallel with the master The OB SLAVE L1 FX is considered L1 phase where the hot AC lines are colored black OB SLAVE L2 Not recommended for EXPORT FX s 3PH MASTER Set the stack phase of the FX you want as the master to 3PH Master and make sure it is in port 1 of the HUB 3 phase systems have a maximum of 3 inverters one master and two slaves Each FX acts independently and cannot help out other phases The HUB has a jumper on it that needs to be changed for 3 phase stacking The 3PH MASTER FX is considered phase A where the hot AC lines are colored black 3PH SLAVE Set the stack phase of the two FX s you want as the slaves to 3PH SLAVE and make sure they are in ports 2 and 3 of the HUB There are no selections within the MATE to differentiate between phase B or phase C When you set the jumper in the HUB for 3 phase the HUB tells each slave which phase they are The 3PH SLAVE on HUB port 2 is considered phase B where the hot AC lines are colored red The 3PH SLAVE on HUB port 3 is considered phase C where the hot AC lines are colored blue Stack Phase Mate Label What it means 0 1 2 PH Master am the master Put
114. the product type choose product lt FX gt FX inverter charger system MX MX60 PV MPPT charge controller FX MX STATUS FX PAGE1 lt MODES gt Shows status and allows adjustment of Inverter AC input Charger Aux and EQ choose category METER Provides the AC voltages and currents of the FX BATT Provides the battery voltage and charger set points and timers MODES METER BATT PG2 PG2 Displays additional sections ERRORS WARNINGS and PG3 STATUS FX MODE P00 The INV CONTROL screen lets you see the status of the inverter function of the FX Pressing the IA Cone role ON STAT button returns you to the first page of the status menu Pressing the CHANGE MODE button CHANGE opens a screen that gives the options of turning the inverter OFF turning the inverter ON or putting DOWN STAT MODE PORT the inverter into SEARCH Pressing PORT will access the next FX if a HUB is present The AC IN CONTROL screen lets you see if the FX will accept an AC source at its input terminals STATUS FX MODE P00 Pressing the UP button returns you to the previous page of the MODES menu Pressing the ac in control USI CHANGE MODE button opens a screen that gives the options of rejecting an AC source by pressing CHR IGE DROP or accepting an AC source by pressing USE Pressing PORT will access the next FX if a DOWN UPT MODE SEOBI HUB is present td The CHR CONTROL screen lets you see what mode the charger is in Pressing the UP button return
115. to trip or the FX to shut off its AC output A MATE must be connected to adjust any parameters or to display any meters Once the FX has been programmed using the MATE the MATE can be disconnected The programming will be saved within the FX s non volatile memory even if the FX is completely shut down AC HOT QUT AC LOADS 230VAC 30 AMPS Ev MAX CBI 30 AMP smie BYPASS WITH ONE CBI 30 AMP OUTPUT BREAKER ONE CBI 30 AMP INPUT BREAKER 30 AMPS AX AC HOT IN AC SOURCE 230VAC NEUTRAL AC BOX DC Box 2 2 3KW amp 230VAC 2 6 3KW 230VAC lat BREAKERS SHOWN c 304 MAX 1 POLE SEN EN VENTED BYPASS MECHANISM AC LOADS geen oa BYPASS lev 2504 BRKRS 12V 250A BRKRS AND TERMINAL ce Je NE 24Vi 175A BRKRS 4Vi 175A BRKRS PRECES ARE MUSED 1 3 jm m ume 3 A p SENG E eae 48V 1004 BRKRS 48V 1754 BRKRS gg BREAKERS LE CI achk 2KW I FX20I2E 1 FX2024E Power Systems AC SOURCE boa MAX CD 304 PR ATTERY 23KW 1 FX2348E ge 230VAC NPUT aa o KW 1 VFX26 Resa 230VAC p j BREAKERS 26KW I VF Xe6lee 360 435 6030 3KW 1 VFX3024E 1 VFX3048E 2 akw 30a BYPASS NOTES The AC OUTPUT NEUTRAL IS NOT BONDED TO THE CHASSIS OR THE GROUND TERMIN
116. tteries The user must carefully watch for when the FX s reaches the Absorb Setpoint voltage and record the current time Next the user should watch the Charger Current screen found by following the path MAIN STATUS FX METER and pressing DOWN four times When the value on the screen matches the AC Current value that was calculated then again record the current time The appropriate Absorb Time Limit for the system is the difference between these two times round this value up if necessary Follow the path MAIN ADV any button PASSWORD 141 FX CHGR DOWN DOWN to get to the Absorb Time Limit screen and use the INC or DEC buttons to adjust the value If there is another source solar wind hydro etc charging the batteries then the Absorb Time Limit can be reduced It is up to the user to decide or the System Design Specialist to set the Absorb Time Limit if this is the case Battery Charging Operation The FX s battery charger includes five stages The first stage BULK raises the battery voltage to the Absorb Setpoint The second stage ABSORB sustains the battery voltage at the Absorb Setpoint for the Absorb Time Limit The charger then goes into the third stage SILENT mode no charging until the battery voltage drops to the Float Setpoint This fourth stage FLOAT sustains this battery voltage for the Float Time Period The charger then goes into Sil
117. ualizing process has started you can stop it at anytime by selecting lt STOP gt from this same control screen Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 3 1 MATE MENU MAP MATE s FX Screens MAIN MENU SUM STATUS SETUP ADV ADVANCED MENU FX MX MATE MAIN Advanced Menu SUMMARY continued on next page SCREEN STATU S FX PG1 STATUS FX PG2 STATUS FX PG3 MODES METER BATT PG2 PG1 ERROR WARN PG3 PG2 DISCON SELL MAIN METER SEARCH INPUT MAIN BATT SETUP FX Fax 360 435 6019 OutBack Power Systems Inc Tel 360 435 6030 19009 62 Ave NE Arlington WA 98223 USA Copyright 2003 07 02 04 FX amp VFX E Series I nverter C harger System Rev 7 0 Installation amp Programming Manual Page 32 MATE MENU MAP ANI ATY LOd XA AOY 9d dOH2 ANI L9Od COd Xs ADV gt T S 3 m T 2 2 o 7 m s x gt Z g gt w g gt lt x b lt s z 9 O 3 m 0 5 8 m z 2 Z 8 gt 3 z E o o o M tN FOd MOYVIS XNY ZOd TaS 30 LOd XA AOY O pb Z Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA
118. udes a AC IN hot key to allow direct control of the AC input from anywhere in the menu system The AC IN key is located on the left side of the MATE s LCD display Above the AC IN key is a yellow LED indicator which flashes when an AC source is available but not connected and is on continuously when the AC source is connected If no AC source is available the yellow LED indicator will remain off The screens shown on this page apply to the MATE the MATE B and the MATE 2 only AC INPUT CONTROL Pressing the AC IN key once brings up the AC INPUT CONTROL screen USE enables the currently USE inverter to connect to the AC source when it is available DROP disconnects the AC source but will allow it to be reconnected if the battery gets too low or the inverter is overloaded DROP USE OK Pressing the AC IN key a second time brings up the GEN START CONTROL screen This allows operation of the generator either manually or automatically using the Advanced GEN START CONTROL Generator Start AGS functions The generators starting circuitry must be connected to the currently MAN OFF AUX ports of the control terminal block see pages 12 amp 13 to use this screen to manually turn the generator ON or OFF or to let the FX automatically perform the AGS functions When the OFF AUTO ON OK AGS functions have not been programmed the screen will show MAN OFF indicating that the generator is controlled manually and is OFF
119. unication cable with RJ45 modular 8 conductor jacks This wiring is considered to be low voltage limited energy circuitry All cabling from the FX and MX60 communication ports to the HUB is made with CAT5 type ethernet communication cabling The maximum distance from the HUB 4 to the FX or MX 60 should be less than 10 feet OutBack includes two 3 foot 1 meter and two 6 foot 2 meter long CAT5 cables standard with the HUB 4 OutBack includes two 3 foot 1 meter long and four 6 foot 2 meter long CAT5 cables standard with the HUB 10 Check with your OutBack dealer for additional cables l SLAVE SLAVE SLAVE SLAVE There is a limit of ten FX s when operated as a stacked system A total of up to ten OutBack products plus one MATE displays can be used with a HUB 10 shown above The HUB 4 will only accept four OutBack products plus one MATE Installation amp Programming M anual FX amp VFX E Series I nverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Page 16 Rev7 0 07 02 04 Tel 360 435 6030 Fax 360 435 6019 TURBO KIT INFORMATION The Turbo Kit is an addition that can be added to any sealed FX It is highly recommended in hot climates
120. ured value This value can be raised up to 4 vac by pressing the INC button and lowered up to 4 vac by pressing the DEC button NOTE Only affects MATE s voltage display See page 44 ADJ OUTPUT VOLTAGE for actual adjustment of inverter VAC output The BATTERY VDC ADJ USTMENT allows calibration of the battery voltage If the battery voltage is measured and is different than the value read from the MATE the user can adjust the reading to match the measured value This value can be raised by pressing the INC button Conversely this value can be lowered by pressing the DEC button The value can be raised or lowered 0 2 vdc Selecting TOP returns the user to the top of the ADV FX CALIBRATION menu section Selecting ADV returns you to the advanced screen to allow selection of another product connected to the MATE Selecting MAIN returns the display to the MAIN screen END OF ADVANCED MENU SYSTEM Installation amp Programming Manual Page 53 FX amp FX Series Inverter Charger System Rev 7 0 07 02 04 WIRE SIZES The following chart contains information on wire sizes the DC resistance of the wires and the corresponding diameters and areas of these wires This information can be used to calculate the voltage drop of the wires or to find an equivalent wire size Se Resiotnce CROSS SECTIONAL AREA a sats AWG in Ohms SQUARE SQUARE INCHES MILLIMETERS 1000 feet INCHES MILL
121. urns the display to the MAIN screen FX amp VFX E Series Inverter C harger System Installation amp Programming Manual Rev 7 0 07 02 04 Page 47 MATE ADVANCED GEN The GEN generator category of the advanced menu section allows for adjustment of the AC input voltage window and time delays to match the characteristics of the AC source if that AC source is a generator This setting can be found in the SETUP FX INPUT menu All OutBack Power System FX s other than the Grid Tie FX s have a default of GEN generator as the AC source ADV choose product FX MATE ADV FX PAGE1 choose category ADV INV CHGR PG2 ADV FX PAGE2 choose category PG1 GRID GEN PG3 ADV FX GEN POO ac input 00 5 min connect delay DOWN INC DEC PORT ADV FX GEN POO ac2 gen 208 vac lower limit DOWN INC DEC PORT ADV FX GEN POO ac2 gen upper limit DOWN INC DEC PORT ADV FX GEN POO ac2 gen input limit DOWN INC DEC PORT ADV FX GEN POO ac2 gen 60 cycles transfer delay DOWN INC DEC PORT ADV FX GEN POO ac2 gen support DOWN OFF ON PORT ADV FX GEN GEN programming completed TOP ADV MAIN Installation amp Programming Manual Page 48 Once the password has been correctly entered the ADV CHOOSE PRODUCT is displa
122. urrents of the FX BATT Provides the battery voltage and charger set points and timers lt PG2 gt Displays additional sections ERRORS WARNINGS and PG3 PG1 Returns to page 1 of the STATUS section lt ERROR gt Displays the different causes for errors and qualifies each cause with a Yes or No WARN Displays the different causes for warnings and qualifies each with a Yes or No PG3 Displays additional sections reason for last DISCONNECT and SELL LOW OUTPUT AC VOLTAGE indicates that the inverter was not able to maintain adequate AC output voltage 200 VAC or above to power the loads connected This typically is caused by the load demanding more power than the inverter is able to deliver STACKING ERROR DETECTED indicates that a problem has occurred with the communication cabling between stacked FX s or if the FX s are stacked incorrectly Check the stacking programming If this condition persists contact your dealer for servicing instructions INVERTER OVERTEMP indicates that the FX reached its maximum allowed operating temperature This can be caused by powering large AC loads or charging for too long It can also be caused by restricting the amount of air which is able to flow around the casting or operation in high temperature environments The inverter will automatically reset and resume operation once it cools down LOW BATTERY VOLTAGE indicates that the battery voltage dropped below the LOW BATTERY CUT OUT VOLTAGE set point 10 5 v
123. utBack Power Systems will repair or replace products covered under this limited warranty that are returned to OutBack Power Systems facility or to an OutBack Power Systems authorized repair facility or that are repaired on site by an OutBack Power Systems authorized repair technician To request limited warranty service you must contact OutBack Power Systems at 360 435 6030 within the limited warranty period If limited warranty service is required OutBack Power Systems will issue a Return Material Authorization RMA Number Mark the outside of the package with the RMA number and include a copy of the purchase invoice in the package You must ship the products back to OutBack Power Systems in their original or equivalent packaging prepay shipping charges and insure the shipment or accept the risk of loss or damage during shipment OutBack Power Systems will ship the repaired or replacement products to you freight prepaid if you use an address in the continental United States where applicable Shipments to other locations will be made freight collect Copyright 2003 OutBack Power Systems Inc FX amp VFX E Series Inverter C harger System Installation amp Programming M anual 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Rev 7 0 07 02 04 Page 55 Installation amp Programming Manual FX amp VFX E Series Inverter C harger System Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA
124. voltage level of the battery connected to the DC terminals of the FX This can be useful in troubleshooting the FX These battery status LED s operate at the following voltage levels Nominal Battery Voltage LED Color 12 VDC 24 VDC 48 VDC Green 12 5 or higher 25 0 or higher 50 0 or higher Yellow 11 5 to 12 5 23 0 to 25 0 46 0 to 50 0 Red 11 5 or lower 23 0 or lower 46 0 or lower There is another set of three LED s which indicates the operation of the FX These LED s are active as follows LED Color LED Action LED Indicates Green Solid GREEN Inverter ON Flashing GREEN Search Mode or Slave Power Save Off Inverter OFF Yellow Solid YELLOW AC Source is Connected Flashing YELLOW AC Input Live Waiting to Connect to the FX Off No AC Input Present Red Solid RED Error An Error Message will be automatically displayed on the MATE Flashing RED Warning A non critical fault happened to the FX The MATE can access this info INVERTER ON OFF The left two terminals of the green terminal block marked INVERTER and ON OFF can be used to control the inverter Connecting the two terminals together through a switch will allow control of the inverter output if a MATE is not available A small jumper wire is pre installed into these two positions of the terminal block and needs to be removed in order to add the external switch If the FX s AC output is off check that the jumper wire is present and well connected An installed switch overrides the contr
125. yed Selecting lt FX gt allows adjustment of the FX s advanced programming Selecting lt PG2 gt advances the user to the second page of the advanced menu Selecting lt GEN gt allows adjustment of the AC input set points and operation The AC INPUT CONNECT DELAY set point adjusts the time period of when the FX sees an acceptable AC source to when it connects the AC loads to that source This is useful to allow a generator to warm up This setting has a range between 0 2 minutes to 15 minutes in 0 1 minute increments The AC2 GEN LOWER LIMIT set point allows adjustment of the minimum voltage that the AC source is allowed to be in order for the FX to connect to that source The FX will back off the charger if the AC source is at this lower limit If the AC source falls below this limit the FX will disconnect from the AC source until it is above this value This setting has a range between 80 vac and 220 vac in 2 vac increments The AC2 GEN UPPER LIMIT set point allows adjustment of the maximum voltage that the AC source is allowed to be in order for the FX to connect to that source If the AC source exceeds this value the FX will disconnect from the AC source until it is below this value This setting has a range between 250 vac and 300 vac in 2 vac increments The AC2 GEN INPUT LIMIT sets the maximum amount of current the FX allows to be drawn from the AC source When the AC input current limit is reached the power draw of the battery ch

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